The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Category: Machine Shop

Mechanical widgetry

  • Vacuum Tube LEDS: Neopixel Plate Cap

    [Edit: Welcome Hackaday! You might prefer real vacuum tubes; searching for “vacuum tube leds” will turn up more posts about this long-running project. And, yes, I lit up a tube, just for old time’s sake, and have some plans for that huge triode.]

    A single (knockoff) Neopixel hovers over a defunct halogen bulb:

    Vacuum Tube LEDs - plate lead - overview
    Vacuum Tube LEDs – plate lead – overview

    The Arduino code comes from stripping down the Hard Drive Platter Mood Light to suit just one Neopixel, with the maximum PWM values favoring the red-blue-purple end of the color wheel:

    	Pixels[RED].Prime = 3;
    	Pixels[GREEN].Prime = 5;
    	Pixels[BLUE].Prime = 7;
    	printf("Primes: (%d,%d,%d)\r\n",Pixels[RED].Prime,Pixels[GREEN].Prime,Pixels[BLUE].Prime);
    
    	Pixels[RED].MaxPWM = 255;
    	Pixels[GREEN].MaxPWM = 64;
    	Pixels[BLUE].MaxPWM = 255;
    

    Unlike the Mood Light’s dozen Neopixels jammed into the platter’s hub ring, running one Neopixel at full throttle atop the tube doesn’t overheat the poor controller. In a 22 °C room, PWM 255 white raises the cap’s interior temperature to 35 °C, which looks like a horrific 40 °C/W thermal coefficient if you figure the dissipation at 300 mW = 5 V x 60 mA.

    Feeding those parameters into the raised sine wave equation causes the cap to tick along at 27 °C for an average dissipation of 120 mW, which sounds about right:

    113 mW = 5 V x (20 + 20 + 5 mA) / 2

    The effect is striking in a dark room, but it’s hard to photograph; the halogen capsule inside the bulb resembles a Steampunk glass jellyfish:

    Vacuum Tube LEDs - plate lead - detail
    Vacuum Tube LEDs – plate lead – detail

    That ceramic light socket should stand on a round base with room for the Arduino controller. I think powering it from a wall wart through a USB cable makes sense, with a USB-to-serial converter epoxied inside the box for reprogramming.

    It looks pretty good, methinks, should you like that sort of thing.

    The Arduino source code as a GitHub gist:

    // Neopixel mood lighting for vacuum tubes
    // Ed Nisley – KE4ANU – January 2016
    #include <Adafruit_NeoPixel.h>
    //———-
    // Pin assignments
    const byte PIN_NEO = 6; // DO – data out to first Neopixel
    const byte PIN_HEARTBEAT = 13; // DO – Arduino LED
    //———-
    // Constants
    #define UPDATEINTERVAL 25ul
    const unsigned long UpdateMS = UPDATEINTERVAL – 1ul; // update LEDs only this many ms apart minus loop() overhead
    // number of steps per cycle, before applying prime factors
    #define RESOLUTION 100
    // want to randomize the startup a little?
    #define RANDOMIZE true
    //———-
    // Globals
    // instantiate the Neopixel buffer array
    Adafruit_NeoPixel strip = Adafruit_NeoPixel(1, PIN_NEO, NEO_GRB + NEO_KHZ800);
    uint32_t FullWhite = strip.Color(255,255,255);
    uint32_t FullOff = strip.Color(0,0,0);
    struct pixcolor_t {
    byte Prime;
    unsigned int NumSteps;
    unsigned int Step;
    float StepSize;
    byte MaxPWM;
    };
    unsigned int PlatterSteps;
    // colors in each LED
    enum pixcolors {RED, GREEN, BLUE, PIXELSIZE};
    struct pixcolor_t Pixels[PIXELSIZE]; // all the data for each pixel color intensity
    unsigned long MillisNow;
    unsigned long MillisThen;
    //– Figure PWM based on current state
    byte StepColor(byte Color, float Phi) {
    byte Value;
    Value = (Pixels[Color].MaxPWM / 2.0) * (1.0 + sin(Pixels[Color].Step * Pixels[Color].StepSize + Phi));
    // Value = (Value) ? Value : Pixels[Color].MaxPWM; // flash at dimmest points
    return Value;
    }
    //– Helper routine for printf()
    int s_putc(char c, FILE *t) {
    Serial.write(c);
    }
    //——————
    // Set the mood
    void setup() {
    pinMode(PIN_HEARTBEAT,OUTPUT);
    digitalWrite(PIN_HEARTBEAT,LOW); // show we arrived
    Serial.begin(57600);
    fdevopen(&s_putc,0); // set up serial output for printf()
    printf("Vacuum Tube Mood Light with Neopixels\r\nEd Nisley – KE4ZNU – January 2016\r\n");
    /// set up Neopixels
    strip.begin();
    strip.show();
    // lamp test: a brilliant white dot
    printf("Lamp test: flash white\r\n");
    for (byte i=0; i<3 ; i++) {
    for (int j=0; j < strip.numPixels(); j++) { // fill LEDs with white
    strip.setPixelColor(j,FullWhite);
    }
    strip.show();
    delay(500);
    for (int j=0; j < strip.numPixels(); j++) { // fill LEDs with black
    strip.setPixelColor(j,FullOff);
    }
    strip.show();
    delay(500);
    }
    // set up the color generators
    MillisNow = MillisThen = millis();
    if (RANDOMIZE)
    randomSeed(MillisNow + analogRead(7));
    else
    printf("Start not randomized\r\n");
    printf("First random number: %ld\r\n",random(10));
    Pixels[RED].Prime = 3;
    Pixels[GREEN].Prime = 5;
    Pixels[BLUE].Prime = 7;
    printf("Primes: (%d,%d,%d)\r\n",Pixels[RED].Prime,Pixels[GREEN].Prime,Pixels[BLUE].Prime);
    Pixels[RED].MaxPWM = 255;
    Pixels[GREEN].MaxPWM = 64;
    Pixels[BLUE].MaxPWM = 255;
    for (byte c=0; c < PIXELSIZE; c++) {
    Pixels[c].NumSteps = RESOLUTION * (unsigned int) Pixels[c].Prime;
    Pixels[c].Step = (RANDOMIZE) ? random(Pixels[c].NumSteps) : (3*Pixels[c].NumSteps)/4;
    Pixels[c].StepSize = TWO_PI / Pixels[c].NumSteps; // in radians per step
    printf("c: %d Steps: %d Init: %d",c,Pixels[c].NumSteps,Pixels[c].Step);
    printf(" PWM: %d\r\n",Pixels[c].MaxPWM);
    }
    }
    //——————
    // Run the mood
    void loop() {
    MillisNow = millis();
    if ((MillisNow – MillisThen) > UpdateMS) {
    digitalWrite(PIN_HEARTBEAT,HIGH);
    for (byte c=0; c < PIXELSIZE; c++) { // step to next increment in each color
    if (++Pixels[c].Step >= Pixels[c].NumSteps) {
    Pixels[c].Step = 0;
    printf("Cycle %d steps %d at %8ld delta %ld ms\r\n",c,Pixels[c].NumSteps,MillisNow,(MillisNow – MillisThen));
    }
    }
    byte Value[PIXELSIZE];
    for (byte c=0; c < PIXELSIZE; c++) { // … for each color
    Value[c] = StepColor(c,0.0); // figure new PWM value
    // Value[c] = (c == RED && Value[c] == 0) ? Pixels[c].MaxPWM : Value[c]; // flash highlight for tracking
    }
    uint32_t UniColor = strip.Color(Value[RED],Value[GREEN],Value[BLUE]);
    for (int j=0; j < strip.numPixels(); j++) { // fill LEDs with color
    strip.setPixelColor(j,UniColor);
    }
    strip.show();
    MillisThen = MillisNow;
    digitalWrite(PIN_HEARTBEAT,LOW);
    }
    }
    view raw TubeMood.ino hosted with ❤ by GitHub
  • Vacuum Tube LEDS: Ersatz Plate Cap

    Lighting up that old voltage regulator tube conclusively demonstrated there’s no point in conjuring high voltages in this day & age. Nay, verily, merely lighting the filament of some tubes would require more power than seems reasonable.

    1B3GT high-voltage regulator tube in the Box o’ Hollow State Electronics suggested a different approach:

    1B3GT HV tube regulator
    1B3GT HV tube regulator

    With only a slight loss of historical accuracy, one could light the tube from the top with a Neopixel LED tucked into a similar cap, with power-and-data arriving through a suitably antiqued flying lead. That won’t work on tubes like that 1B3GT with an actual plate terminal  at the top, nor with small Noval / miniature 7-pin tubes topped with an evacuation tip, but it’s fine for tubes like this 6SN7GTB:

    6SN7GTB Vacuum Tube
    6SN7GTB Vacuum Tube

    Obviously, you want a relatively small cap atop the tube, lest the LED visually overwhelm the tube. Some preliminary tests (a.k.a. screwing around) showed that the mica spacer holding the dual triode elements together lights up wonderfully well and diffuses the glow throughout the tube.

    Adafruit has relatively large round (and smaller roundish) Neopixel breakout boards, but I bought a bunch of knockoff Neopixels mounted on a 10 mm circular PCB from the usual eBay supplier:

    Vacuum Tube LEDs - plate lead - connections
    Vacuum Tube LEDs – plate lead – connections

    Some PET braid tucked into a snippet of brass tubing dresses up a length of what might once have been audio cable. The braid wants to fray on the ends; confining it with heatstink or brass tubing is mandatory.

    That’s a 1 µF ceramic SMD cap soldered between the +5 V and Gnd traces, atop a snippet of Kapton tape, in the hopes that it will help the 100 nF cap (on the other side of the board) tamp down the voltage dunks from PWM current pulses through that long thin wire. The leads come off toward the center to bend neatly upward into the cap.

    Duplicating that old plate cap on the 1B3GT would be a fool’s errand, so I went full frontal Vader:

    Vacuum Tube Lights - cap solid model - Overview
    Vacuum Tube Lights – cap solid model – Overview

    The interior recesses the LED far enough to allow for the tube’s top curvature, with a conical adapter to the smaller wiring channel that allows for more plastic supporting the brass tube:

    Vacuum Tube Lights - cap solid model - section
    Vacuum Tube Lights – cap solid model – section

    A glob of epoxy inside the cap anchors the PCB and fuses all the loose ends / floppy wires / braid strands into a solid block that will never come apart again.

    It should be printed (or primered and painted) with opaque black or maybe Bakelite Brown, but right now I have cyan PETG and want to see how it plays, soooo:

    Vacuum Tube LEDs - plate lead - overview
    Vacuum Tube LEDs – plate lead – overview

    The cap floats in mid-air over a defunct Philips 60 W halogen bulb that I’ve been saving for just such an occasion. Obviously, you must epoxy / glue the cap in place for a permanent display.

    The OpenSCAD source code as a Github gist:

    // Vacuum Tube LED Lights
    // Ed Nisley KE4ZNU January 2016
    Layout = "Cap"; // Show Build Cap Box Octal Noval Mini7
    Section = true; // cross-section the object
    //- Extrusion parameters must match reality!
    ThreadThick = 0.25;
    ThreadWidth = 0.40;
    HoleWindage = 0.2;
    Protrusion = 0.1; // make holes end cleanly
    inch = 25.4;
    function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
    //———————-
    // Dimensions
    // https://en.wikipedia.org/wiki/Tube_socket#Summary_of_Base_Details
    T_NAME = 0;
    T_NUMPINS = 1; // Socket specifications
    T_PINCIRC = 2;
    T_PINDIA = 3;
    T_SOCKDIA = 4;
    TubeBase = [
    ["Mini7", 8, 9.53, 1.016, 19.0],
    ["Octal", 8, 17.45, 2.36, 33.0],
    ["Noval",10, 11.89, 1.1016,20.5],
    ];
    ID = 0;
    OD = 1;
    LENGTH = 2;
    Pixel = [7.0,10.0,3.0]; // ID = contact patch, OD = PCB dia, LENGTH = overall thickness
    //———————-
    // Useful routines
    module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
    Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
    FixDia = Dia / cos(180/Sides);
    cylinder(r=(FixDia + HoleWindage)/2,
    h=Height,
    $fn=Sides);
    }
    //———————-
    // Tube cap
    CapTube = [4.0,3/16 * inch,10.0]; // brass tube for flying lead to cap LED
    CapSize = [Pixel[ID],(Pixel[OD] + 3.0),(CapTube[OD] + 2*Pixel[LENGTH])];
    CapSides = 6*4;
    module Cap() {
    difference() {
    union() {
    cylinder(d=CapSize[OD],h=(CapSize[LENGTH]),$fn=CapSides); // main cap body
    translate([0,0,CapSize[LENGTH]]) // rounded top
    scale([1.0,1.0,0.65])
    sphere(d=CapSize[OD]/cos(180/CapSides),$fn=CapSides); // cos() fixes slight undersize vs cylinder
    cylinder(d1=(CapSize[OD] + 2*3*ThreadWidth),d2=CapSize[OD],h=1.5*Pixel[LENGTH],$fn=CapSides); // skirt
    }
    translate([0,0,-Protrusion]) // bore for wiring to LED
    PolyCyl(CapSize[ID],(CapSize[LENGTH] + 3*ThreadThick + Protrusion),CapSides);
    translate([0,0,-Protrusion]) // PCB recess with clearance for tube dome
    PolyCyl(Pixel[OD],(1.5*Pixel[LENGTH] + Protrusion),CapSides);
    translate([0,0,(1.5*Pixel[LENGTH] – Protrusion)]) // step + cone to retain PCB
    cylinder(d1=(Pixel[OD]/cos(180/CapSides)),d2=Pixel[ID],h=(Pixel[LENGTH] + Protrusion),$fn=CapSides);
    translate([0,0,(CapSize[LENGTH] – CapTube[OD]/(2*cos(180/8)))]) // hole for brass tube holding wire loom
    rotate([90,0,0]) rotate(180/8)
    PolyCyl(CapTube[OD],CapSize[OD],8);
    }
    }
    //———————-
    // Build it
    if (Layout == "Cap") {
    if (Section)
    difference() {
    Cap();
    translate([-CapSize[OD],0,CapSize[LENGTH]])
    cube([2*CapSize[OD],2*CapSize[OD],3*CapSize[LENGTH]],center=true);
    }
    else
    Cap();
    }
    if (Layout == "Build") {
    Cap();
    Spigot();
    }
  • Poughkeepsie ACM Chapter Presentation: Plotting Like It’s 1989!

    I’ll be giving an in-depth talk about my adventures restoring that old HP 7475A plotter for the Poughkeepsie ACM Chapter at Marist College this evening:

    Superformula Plot - Composite D
    Superformula Plot – Composite D

    This being the Association for Computing Machinery, I will talk a bit about the Superformula that makes it all possible:

    Gielis Superformula - parameters
    Gielis Superformula – parameters

    The presentation will look a lot like this: ACM – Plotting Like Its 1989. The PDF doesn’t include my patter, but perhaps the linky love on each screen can fill in the details.

    If you’re following along, the Python source code running on the plotter as a GitHub Gist:

    from chiplotle import *
    from math import *
    from datetime import *
    from time import *
    from types import *
    import random
    def superformula_polar(a, b, m, n1, n2, n3, phi):
    ''' Computes the position of the point on a
    superformula curve.
    Superformula has first been proposed by Johan Gielis
    and is a generalization of superellipse.
    see: http://en.wikipedia.org/wiki/Superformula
    Tweaked to return polar coordinates
    '''
    t1 = cos(m * phi / 4.0) / a
    t1 = abs(t1)
    t1 = pow(t1, n2)
    t2 = sin(m * phi / 4.0) / b
    t2 = abs(t2)
    t2 = pow(t2, n3)
    t3 = -1 / float(n1)
    r = pow(t1 + t2, t3)
    if abs(r) == 0:
    return (0, 0)
    else:
    # return (r * cos(phi), r * sin(phi))
    return (r, phi)
    def supershape(width, height, m, n1, n2, n3,
    point_count=10 * 1000, percentage=1.0, a=1.0, b=1.0, travel=None):
    '''Supershape, generated using the superformula first proposed
    by Johan Gielis.
    – `points_count` is the total number of points to compute.
    – `travel` is the length of the outline drawn in radians.
    3.1416 * 2 is a complete cycle.
    '''
    travel = travel or (10 * 2 * pi)
    # compute points…
    phis = [i * travel / point_count
    for i in range(1 + int(point_count * percentage))]
    points = [superformula_polar(a, b, m, n1, n2, n3, x) for x in phis]
    # scale and transpose…
    path = []
    for r, a in points:
    x = width * r * cos(a)
    y = height * r * sin(a)
    path.append(Coordinate(x, y))
    return Path(path)
    # RUN DEMO CODE
    if __name__ == '__main__':
    override = False
    plt = instantiate_plotters()[0]
    # plt.write('IN;')
    if plt.margins.soft.width < 11000: # A=10365 B=16640
    maxplotx = (plt.margins.soft.width / 2) – 100
    maxploty = (plt.margins.soft.height / 2) – 150
    legendx = maxplotx – 2900
    legendy = -(maxploty – 750)
    tscale = 0.45
    numpens = 4
    # prime/10 = number of spikes
    m_values = [n / 10.0 for n in [11, 13, 17, 19, 23]]
    # ring-ness 0.1 to 2.0, higher is larger
    n1_values = [
    n / 100.0 for n in range(55, 75, 2) + range(80, 120, 5) + range(120, 200, 10)]
    else:
    maxplotx = plt.margins.soft.width / 2
    maxploty = plt.margins.soft.height / 2
    legendx = maxplotx – 3000
    legendy = -(maxploty – 900)
    tscale = 0.45
    numpens = 6
    m_values = [n / 10.0 for n in [11, 13, 17, 19, 23, 29, 31,
    37, 41, 43, 47, 53, 59]] # prime/10 = number of spikes
    # ring-ness 0.1 to 2.0, higher is larger
    n1_values = [
    n / 100.0 for n in range(15, 75, 2) + range(80, 120, 5) + range(120, 200, 10)]
    print " Max: ({},{})".format(maxplotx, maxploty)
    # spiky-ness 0.1 to 2.0, higher is spiky-er (mostly)
    n2_values = [
    n / 100.0 for n in range(10, 60, 2) + range(65, 100, 5) + range(110, 200, 10)]
    plt.write(chr(27) + '.H200:') # set hardware handshake block size
    plt.set_origin_center()
    # scale based on B size characters
    plt.write(hpgl.SI(tscale * 0.285, tscale * 0.375))
    # slow speed for those abrupt spikes
    plt.write(hpgl.VS(10))
    while True:
    # standard loadout has pen 1 = fine black
    plt.write(hpgl.PA([(legendx, legendy)]))
    pen = 1
    plt.select_pen(pen)
    plt.write(hpgl.PA([(legendx, legendy)]))
    plt.write(hpgl.LB("Started " + str(datetime.today())))
    if override:
    m = 4.1
    n1_list = [1.15, 0.90, 0.25, 0.59, 0.51, 0.23]
    n2_list = [0.70, 0.58, 0.32, 0.28, 0.56, 0.26]
    else:
    m = random.choice(m_values)
    n1_list = random.sample(n1_values, numpens)
    n2_list = random.sample(n2_values, numpens)
    pen = 1
    for n1, n2 in zip(n1_list, n2_list):
    n3 = n2
    print "{0} – m: {1:.1f}, n1: {2:.2f}, n2=n3: {3:.2f}".format(pen, m, n1, n2)
    plt.select_pen(pen)
    plt.write(hpgl.PA([(legendx, legendy – 100 * pen)]))
    plt.write(
    hpgl.LB("Pen {0}: m={1:.1f} n1={2:.2f} n2=n3={3:.2f}".format(pen, m, n1, n2)))
    e = supershape(maxplotx, maxploty, m, n1, n2, n3)
    plt.write(e)
    pen = pen + 1 if (pen % numpens) else 1
    pen = 1
    plt.select_pen(pen)
    plt.write(hpgl.PA([(legendx, legendy – 100 * (numpens + 1))]))
    plt.write(hpgl.LB("Ended " + str(datetime.today())))
    plt.write(hpgl.PA([(legendx, legendy – 100 * (numpens + 2))]))
    plt.write(hpgl.LB("More at https://softsolder.com/?s=7475a&quot;))
    plt.select_pen(0)
    plt.write(hpgl.PA([(-maxplotx,maxploty)]))
    print "Waiting for plotter… ignore timeout errors!"
    sleep(40)
    while NoneType is type(plt.status):
    sleep(5)
    print "Load more paper, then …"
    print " … Press ENTER on the plotter to continue"
    plt.clear_digitizer()
    plt.digitize_point()
    plotstatus = plt.status
    while (NoneType is type(plotstatus)) or (0 == int(plotstatus) & 0x04):
    plotstatus = plt.status
    print "Digitized: " + str(plt.digitized_point)

     

  • Ham It Up Noise Source Enable Switch

    Some rummaging produced a tiny DPDT switch that actually fit the holes intended for a pin header on the recently arrived Ham It Up board, at least after I amputated 2/3 of the poor thing’s legs:

    Ham-It-Up - noise source switch - B
    Ham-It-Up – noise source switch – B

    The new SMA noise output jack sits in the front left, with the white “noise on” LED just left of the switch:

    Ham-It-Up - noise source switch - A
    Ham-It-Up – noise source switch – A

    There’s no way to measure these things accurately, at least as far as I can tell, but the holes came out pretty close to where they should be. The new SMA connector lined up horizontally with the existing IF output jack and vertically with the measured / rounded-to-the-nearest-millimeter on-center distance:

    Ham It Up - noise SMA drilling
    Ham It Up – noise SMA drilling

    The Enable switch doesn’t quite line up with the LED, so the holes will always look like I screwed up:

    Ham-It-Up - noise source switch - case holes
    Ham-It-Up – noise source switch – case holes

    That’s OK, nobody will ever notice.

    Now, to stack up enough adapters to get from the SMA on the Ham It Up board to the N connector on the spectrum analyzer …

     

  • Lithium Battery Pack Teardown

    For reasons not relevant here, I tore down a battery pack containing three 18650 lithium cells. After a major struggle that involved drilling access holes into the side of the case and hammering the cells free of their silicone potting restraint, I was confronted with this:

    Li-ion cell - unwrapped
    Li-ion cell – unwrapped

    Battery may explode or fire if mistreated. Yeah, that could happen.

    Having pretty well ignored all the warnings, the damaged cells spent two days in the cold on the patio:

    Li-ion cells - safety layout
    Li-ion cells – safety layout

    They seem unchanged, so I’ll dispose of them at the next electronics recycling event.

    As it turns out, the gadget containing the pack subsequently died of a whoopise while trying to figure out how the pack’s boost regulator worked, so it joined the cells on the outgoing pile.

    So it goes …

  • Microscope Stage Positioner

    Given the vanishingly small depth of field provided by a cheap USB camera peering through the stereo zoom microscope, I’ve always wanted a better way of moving objects by small increments. The rehabilitated micropositioner didn’t have the right orientation or end effector:

    Micropositioner
    Micropositioner

    So I rearranged the axis slides and added a small table:

    Microscope Stage Positioner
    Microscope Stage Positioner

    That frees up the magnetic base and husky angle bracket, plus a few odds & ends, for future adventures.

    The clear base is a random chunk of acrylic, bandsawed to the proper length, then tediously squared and drilled on the Sherline:

    Microscope Stage Positioner - base squaring
    Microscope Stage Positioner – base squaring

    I briefly thought of printing the base, but came to my senses: there are better ways to make big flat surfaces.

    The little aluminum table has a nubbly spray coating that came straight from the heap and looks surprisingly good after squaring & drilling. The X axis block puts it below the platform and one screw head above the desk when the Y axis arm sits flat on the acrylic base.

    One solid model view arranges things in more-or-less the proper layout to check the alignment:

    Microscope Stage Positioner - solid model - Show layout
    Microscope Stage Positioner – solid model – Show layout

    The build layout reduces the platform space:

    Microscope Stage Positioner - Slic3r preview
    Microscope Stage Positioner – Slic3r preview

    You’re looking at four hours of PETG print time at 0.2 mm layer thickness with 15% infill and Hilbert Curve surfaces.

    All of the screws have UNF fine-pitch threads (4-48, 6-40, 8-36, stuff like that), so the solid model includes the spacing required to reuse the original screws: those big holes in the Y axis arm end in little clearance holes for the tiny screws. Some of the screws bottom out with barely two millimeters of thread engagement in the slides, while others could jam against the racks. I didn’t want to cut that many screws from my Brownell’s gun screw assortment unless I absolutely had to. So far, so good.

    I spent quite a while doodling the layout to convince myself that it would actually work:

    Microscope Stage Positioner - layout doodle
    Microscope Stage Positioner – layout doodle

    Memo to self: Next time, use a larger scale!

    Although the whole lashup works as intended, those metal hunks are way too heavy for the plastic block that fits between the Z axis drive pillar and the X axis slide: that long Y axis arm drooped toward the front by about 5 mm. A small shim raised the front of the Z axis footprint enough to level the arm, but I think the right answer is a metal upright with a bigger footprint that spreads the load.

    All that mass hanging out in mid-air turns the plastic pieces into springs: you can’t keep your fingers on the knobs. Fortunately, everything returns to the same position after you release the knob, so it’s easy to move in precise increments if you close your eyes until the view settles down.

    There’s a reason optical equipment uses cast iron, steel, and brass… but I’ll settle for plastic.

    The OpenSCAD source code as a GitHub gist:

    // Microscope Stage Positioner
    // Ed Nisley KE4ZNU January 2016
    Layout = "Build"; // Show Build
    // Base ZStand YMount XMount
    Gap = 0.0;
    //- Extrusion parameters must match reality!
    ThreadThick = 0.25;
    ThreadWidth = 0.40;
    HoleWindage = 0.2;
    Protrusion = 0.1; // make holes end cleanly
    inch = 25.4;
    function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
    //———————-
    // Dimensions
    SlipFit = 0.1;
    ZDrive = [26.0,19.6,75.0]; // stationary part of Z drive
    ZDriveOffset =[0,0,22.0]; // left front corner of stationary Z base
    ZWall = 4.0; // thickness of edge wrapped around Z columns
    YStageBlock = [25.0,61.0,17.0]; // Y stage mount + slide
    YStageOffset = [-6.0,4.0,0.0]; // offset to inner corner of Y stage holder
    YArm = [10.0,93.0,17.0]; // mount to stationary part of Y stage
    ZStage = [24.0,9.7,85.0]; // moving part of Z drive
    ZYArm = [(2*ZWall + ZStage[0]),10.0,YArm[2]]; // attaches to ZStage, same thickness as YArm
    XStageBlock = [25.0,20.0,12.0]; // X stage mount + slide
    XStageOffset = [-95.0,-15.0,-26]; // offset to rear left bottom corner of X stage slide
    XTray = [25,25,5]; // X tray attached to bottom of X mount
    //———————-
    // Useful routines
    module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
    Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
    FixDia = Dia / cos(180/Sides);
    cylinder(r=(FixDia + HoleWindage)/2,
    h=Height,
    $fn=Sides);
    }
    //– Z Stand
    module ZStand() {
    Holes = [12.0,41.5,68.0];
    HoleOD = 3.5;
    HolesOC = 15.0;
    echo(str("Z Stand holes OC: ",HolesOC));
    ZPlate = 6.0; // thickness of Z plate = max screw grab distance
    ZStandWrap = 2.0; // length of edge wrapped around Z column
    MaxY = 9.0;
    MinY = -14.0;
    difference() {
    union() {
    linear_extrude(height=ZDriveOffset[2])
    polygon(points=[
    [-ZWall,MaxY], // limited by Z slide rack
    [ZDrive[0] + ZWall,MaxY],
    [ZDrive[0] + ZWall,MinY], // limited by X slide rack
    [-ZWall,MinY]
    ]);
    linear_extrude(height=(ZDrive[2] + ZDriveOffset[2]),convexity=4)
    polygon(points=[
    [-SlipFit,0],
    [ZDrive[0] + SlipFit,0.0],
    [ZDrive[0] + SlipFit,ZStandWrap],
    [ZDrive[0] + ZWall,ZStandWrap],
    [ZDrive[0] + ZWall,-ZPlate],
    [-ZWall,-ZPlate],
    [-ZWall,ZStandWrap],
    [-SlipFit,ZStandWrap]
    ]);
    }
    for (i = [0:len(Holes) – 1]) // holes along Z stand
    translate([ZDrive[0]/2,ZDrive[1]/2,(Holes[i] + ZDriveOffset[2])])
    rotate([90,0,0])
    PolyCyl(HoleOD,ZDrive[1]);
    for (i = [-1,1]) // mounting screw holes
    translate([i*HolesOC/2 + ZDrive[0]/2, // center the holes from side to side
    (MaxY + MinY)/2, // moby hack to put holes on midline
    -Protrusion])
    PolyCyl(3.5,0.75*ZDriveOffset[2],6);
    }
    }
    //– Y Mounting arm
    // Polygon origin at inner corner nearest the Z stand column
    module YMount() {
    YHoles = [12.0,48.0,84.0]; // mounting holes along Y stage arm, from outside in
    YScrewLength = 4.0; // screw head to Y stage mount
    ZStageBase = [(ZDrive[0] – ZStage[0])/2,(ZDrive[1] + ZStage[1]),0.0] – YStageOffset; // local coordinates of Z slide left rear corner
    ZHoles = [26.5,55.0,71.0];
    ZStageWrap = 8.0; // length of edge wrapped around Z stage
    Trim = ZStageBase[1] – ZStageWrap;
    union() {
    difference() {
    linear_extrude(height=YArm[2],convexity=5)
    polygon(points=[
    [-Trim,0.0],
    [-YStageBlock[0],0.0],
    [-YStageBlock[0],-(YArm[1] + SlipFit)],
    [-(YStageBlock[0] + YArm[0]),-(YArm[1] + SlipFit)],
    [-(YStageBlock[0] + YArm[0]),Trim],
    [-Trim,(ZStageBase[1] + ZYArm[1])],
    [(ZStageBase[0] + ZStage[0]/2),(ZStageBase[1] + ZYArm[1])],
    [(ZStageBase[0] + ZStage[0] + ZWall),(ZStageBase[1] + 0*ZYArm[1])],
    [(ZStageBase[0] + ZStage[0] + ZWall),(ZStageBase[1] – ZStageWrap)],
    [(ZStageBase[0] + ZStage[0] + SlipFit),(ZStageBase[1] – ZStageWrap)],
    [(ZStageBase[0] + ZStage[0] + SlipFit),ZStageBase[1]],
    [(ZStageBase[0] – SlipFit),ZStageBase[1]],
    [(ZStageBase[0] – SlipFit),(ZStageBase[1] – ZStageWrap)],
    [0.0,(ZStageBase[1] – ZStageWrap)],
    [0.0,Trim]
    ]);
    for (j=[0:len(YHoles) – 1]) { // Y stage mounting screws
    translate([-(YStageBlock[0] + YScrewLength),
    (-YArm[1] + YHoles[j] – 2*SlipFit),
    YArm[2]/2])
    rotate([0,-90,0]) rotate(180/6)
    PolyCyl(5.5,YArm[0],6);
    translate([-(YStageBlock[0] – Protrusion),
    (-YArm[1] + YHoles[j] – 2*SlipFit),
    YArm[2]/2])
    rotate([0,-90,0]) rotate(180/6)
    PolyCyl(2.5,2*YArm[0],6);
    }
    }
    if (true)
    difference() {
    linear_extrude(height=ZStage[2],convexity=5)
    polygon(points=[
    [(ZStageBase[0] – ZWall),(ZStageBase[1] + 5.0)],
    [(ZStageBase[0] + ZStage[0] + ZWall),(ZStageBase[1] + 5.0)],
    [(ZStageBase[0] + ZStage[0] + ZWall),(ZStageBase[1] – ZStageWrap)],
    [(ZStageBase[0] + ZStage[0] + SlipFit),(ZStageBase[1] – ZStageWrap)],
    [(ZStageBase[0] + ZStage[0] + SlipFit),ZStageBase[1]],
    [(ZStageBase[0] – SlipFit),ZStageBase[1]],
    [(ZStageBase[0] – SlipFit),(ZStageBase[1] – ZStageWrap)],
    [(ZStageBase[0] – ZWall),(ZStageBase[1] – ZStageWrap)],
    ]);
    for (k=[0:len(ZHoles) – 1])
    translate([(ZStageBase[0] + ZStage[0]/2),0.0,ZHoles[k]])
    rotate([-90,0,0])
    PolyCyl(3.5,2*ZStageBase[1],6);
    }
    }
    }
    //– X Slide attachment
    // Origin at left rear bottom of mount
    module XMount() {
    XHoles = [6.0,18.0]; // from end of X slide
    XHolesOffset = 7.0; // from bottom of X slide
    TrayHolesOC = 10.0;
    echo(str("Tray holes OC: ",TrayHolesOC));
    BlockOAH = XStageBlock[2] – XStageOffset[2] – XTray[2]; // overall height of mount
    difference() {
    translate([XStageBlock[0],0,BlockOAH])
    rotate([0,90,180])
    linear_extrude(height=XStageBlock[0],convexity=2)
    polygon(points=[
    [0,0],
    [0.0,7.0],
    [(XStageBlock[2] + SlipFit),7.0],
    [(XStageBlock[2] + SlipFit),XStageBlock[1]],
    [BlockOAH,XStageBlock[1]],
    [BlockOAH,0.0],
    ]);
    for (i=[0:len(XHoles) – 1]) // holes for X stage screws
    translate([XHoles[i],Protrusion,BlockOAH – XStageBlock[2] + XHolesOffset])
    rotate([90,0,0])
    PolyCyl(3.5,2*7.0,6);
    for (i=[-1,1]) // holes for tray mount
    translate([i*TrayHolesOC/2 + XStageBlock[0]/2,-XStageBlock[1]/2,-Protrusion])
    PolyCyl(2.5,0.75*(BlockOAH – XStageBlock[2]),6);
    }
    }
    //———————-
    // Build it
    if (Layout == "ZStand")
    ZStand();
    if (Layout == "YMount")
    YMount();
    if (Layout == "XMount")
    XMount();
    if (Layout == "Show") {
    color("lightgreen")
    ZStand();
    color("orange")
    translate(YStageOffset)
    YMount();
    color("lightblue")
    translate(XStageOffset + [0,0,-XStageOffset[2]])
    XMount();
    }
    if (Layout == "Build") {
    translate([20,0,0])
    ZStand();
    translate([YStageBlock[0]/2,0,0])
    YMount();
    translate([20,-30,0])
    XMount();
    }
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