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.

The New Hotness

  • Square Patio Table Feet

    For a square patio table (with one missing foot), of course:

    Patio Table Feet - installed
    Patio Table Feet – installed

    These are chunky enough to demonstrate they’re made of clear-ish TPU, at least when backlit:

    Patio Table Feet - installed - backlit
    Patio Table Feet – installed – backlit

    The interior of the leg determines what fits into it:

    Patio Table Feet - leg interior
    Patio Table Feet – leg interior

    I pried out another foot, scanned it, and blew out the contrast:

    Patio Table Foot - scan
    Patio Table Foot – scan

    Importing that into LightBurn let me draw a rectangle matching the measured size, then node-edit the corners to approximate the shape:

    Patio Table Foot - LightBurn layout
    Patio Table Foot – LightBurn layout

    Export that shape as an SVG, import into OpenSCAD, and turn it into a solid model:

    Patio Table Foot - solid model - show view
    Patio Table Foot – solid model – show view

    That’s the Show view simulating the actual positions, which demonstrates why the pair of legs at each corner wear mirror-imaged feet. The Build view arranges the pair more sensibly for 3D printing:

    Patio Table Foot - solid model - build view
    Patio Table Foot – solid model – build view

    The protrusions and their bumps went through several iterations on the way to being functional, with the black TPU prototype on the left being entirely too bendy and the first clear version requiring utility knife editing to fit the end posts inside the leg:

    Patio Table Feet - prototypes
    Patio Table Feet – prototypes

    The original feet seem to be injection-molded ABS with a flat bottom intended to erode one corner against whatever the table stands on. However, the legs splay out at 5° from the vertical, which makes the flat bottom I used for the first few iterations obviously wrong:

    Patio Table Feet - flat foot
    Patio Table Feet – flat foot

    Somebody who can math harder than I would resolve the two angles and all the measurements into a single transformation matrix, but I rotated the foot separately around the X and Y axes, trigged the lowest corner to the proper height, then chopped off everything below Z=0. Works for me.

    The OpenSCAD source code as a GitHub Gist:

    // Patio Table Foot – rectangular legs
    // Ed Nisley – KE4ZNU
    // 2026-05-26
    include <BOSL2/std.scad>
    Layout = "Show"; // [Show,Build]
    /* [Hidden] */
    HoleWindage = 0.2;
    Protrusion = 0.01;
    NumSides = 4*3*2*4;
    Gap = 5.0/2;
    $fn=NumSides;
    PadOA = [50,23.5,4.5];
    LegAngles = [5,5];
    EndStrut = [2.5 + 2.5,13.3 – 1.0,23.0];
    SideStrut = [12.0,5.5 – 1.0,13.0];
    Clearance = 0.5;
    StrutsOC = [44.0 – EndStrut.x,18.0 – SideStrut.y];
    //—–
    // Define it
    module Foot(angles = LegAngles) {
    difference() {
    up((PadOA.x/2)*abs(sin(angles.x)) + (PadOA.y/2)*abs(sin(angles.y)))
    xrot(angles.x) yrot(angles.y)
    union() {
    down(3*PadOA.z)
    linear_extrude(4*PadOA.z)
    left(PadOA.x/2) fwd(PadOA.y/2)
    import("Patio Table Foot – pad outline.svg",center=true);
    up(PadOA.z)
    for (i = [-1,1])
    right(i*StrutsOC.x/2)
    cuboid(EndStrut,anchor=BOTTOM) position(TOP)
    down(EndStrut.y/2) left(i*Clearance)
    pie_slice(r=(PadOA.x – StrutsOC.x)/2,ang=180,l=EndStrut.y,anchor=CENTER,spin=-i*90,orient=FRONT);
    up(PadOA.z)
    for (j = [-1,1])
    fwd(j*StrutsOC.y/2)
    cuboid(SideStrut,anchor=BOTTOM) position(TOP)
    down(SideStrut.x/2) zrot(90) right(j*Clearance)
    pie_slice(r=(PadOA.y – StrutsOC.y)/2,ang=180,l=SideStrut.x,anchor=CENTER,spin=j*90,orient=FRONT);
    }
    cuboid(4*PadOA,anchor=TOP);
    }
    }
    //—–
    // Build it
    if (Layout == "Show") {
    back(PadOA.y/2 + Gap)
    Foot();
    left(0.8*PadOA.x) fwd(PadOA.y) zrot(-90)
    yflip() Foot();
    }
    if (Layout == "Build") {
    union() {
    fwd(PadOA.y/2 + Gap)
    Foot();
    back(PadOA.y/2 + Gap)
    yflip() Foot();
    }
    }