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Improved Chain Mail Link

The rectangular posts in my chain mail resemble Zomboe’s original design, but with dimensions computed directly from the bar (and, thus, thread) widths and thicknesses to ensure good fill and simple bridging:

Chain Mail Link

Chain Mail Link

They fit together well, but the angled post edges make the bridge threads longer than absolutely necessary along the outside edge of each link:

Chain Mail Sheet - detail

Chain Mail Sheet – detail

A bit of fiddling produces a squared-off version:

Chain Mail Link - Improved Posts

Chain Mail Link – Improved Posts

Which nest together like this:

Chain Mail - Improved Posts - Bottom View

Chain Mail – Improved Posts – Bottom View

Now all the bridge threads have the same length, which should produce better results.

The OpenSCAD source code for the link:

module BaseLink() {

	render(convexity=2)
		difference() {
			translate([0,0,BaseHeight/2]) {
				difference(convexity=2) {
					intersection() {		// outside shape
						cube([BaseSide,BaseSide,BaseHeight],center=true);
						rotate(45)
							cube([BaseOutDiagonal,BaseOutDiagonal,BaseHeight],center=true);
					}
					intersection() {		// inside shape
						cube([(BaseSide - 2*BarWidth),
							  (BaseSide - 2*BarWidth),
							  (BaseHeight + 2*Protrusion)],
							 center=true);
						rotate(45)
							cube([BaseInDiagonal,
								  BaseInDiagonal,
								  (BaseHeight +2*Protrusion)],
								 center=true);
					}
				}
			}

			translate([0,0,(BaseHeight/2 + BarThick)])
				cube([(BaseSide - 2*BarWidth - 2*BarWidth/sqrt(2)),
					  (2*BaseSide),
					  BaseHeight],
					 center=true);
			translate([0,0,(BaseHeight - BaseHeight/2 - BarThick)])
				cube([(2*BaseSide),
					  (BaseSide - 2*BarWidth - 2*BarWidth/sqrt(2)),
					  BaseHeight],
					 center=true);
		}
}
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