The New Hotness

A laptop-style power brick supplies 24 V for the MPCNC’s stepper motors, but I didn’t want it wandering around on the Basement Laboratory floor and getting in trouble, so a pair of brackets seemed in order:

Power Supply Brick Mount - trial fit — Power Supply Brick Mount – trial fit

They build flat on their backs to avoid support material:

Power Supply Brick Mount - Slic3r — Power Supply Brick Mount – Slic3r

The nicely rounded corners produce a very thin line of plastic on the first layer, so the model now has thicker base plates to improve the situation. A set of mouse ears would keep the tips pasted to the glass.

The OpenSCAD source code as a GitHub Gist:

	// Power Supply Brick brackets
	// Ed Nisley KE4ZNU 2018-02-26

	Layout = "Show";

	//– Extrusion parameters

	ThreadThick = 0.25;
	ThreadWidth = 0.4;

	HoleWindage = 0.3; // enlarge hole dia by this amount

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	Protrusion = 0.1; // make holes look good and joints intersect properly

	//– Useful sizes

	inch = 25.4;

	Tap10_32 = 0.159 * inch;
	Clear10_32 = 0.190 * inch;
	Head10_32 = 0.373 * inch;
	Head10_32Thick = 0.110 * inch;
	Nut10_32Dia = 0.433 * inch;
	Nut10_32Thick = 0.130 * inch;

	ID = 0;
	OD = 1;
	LENGTH = 2;

	//– Bracket Dimensions

	Brick = [170.0,66.0,40.0]; // overall size, add details in module

	Socket = [30.0,24.0]; // IEC power socket
	Cable = [6.0,15.0]; // DC output cable ID=wire OD=strain relief

	WallThick = 3.0; // default wall thickness
	BaseThick = 4.0;

	Screw = [5.1,10.0,3.0]; // screw size, more-or-less 10-32, OD & LENGTH for head

	NumSides = 3*4;

	//———————-
	// 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);
	}

	//———————-
	// Models



	module BrickMount(End="Both") {

	difference() {
	union() {
	hull() // main block
	for (i=[-1,1], j=[-1,1], k=[0,1])
	translate([i*(Brick.x/2 + WallThick – WallThick),
	j*(Brick.y/2 + WallThick – WallThick),
	k*(Brick.z + WallThick – WallThick)])
	sphere(r=WallThick,$fn=NumSides);
	hull() // screw flanges
	for (i=[-1,1], j=[-1,1])
	translate([i*(Brick.x/2 + WallThick – BaseThick),
	j(Brick.y/2 + WallThick + 2Screw[OD] – BaseThick),
	0])
	sphere(r=BaseThick,$fn=NumSides);
	}
	for (i=[-1,1], j=[-1,1]) // remove screw holes
	translate([i*(Brick.x/2 + WallThick – Screw[OD]),
	j*(Brick.y/2 + WallThick + Screw[OD]),
	-Protrusion])
	rotate(180/6)
	PolyCyl(Screw[ID],2*WallThick,6);

	translate([0,0,Brick.z/2]) // remove center part to leave ends
	cube([(Brick.x + 2WallThick – 4Screw[OD]),2Brick.y,2Brick.z],center=true);

	if (End == "Socket")
	translate([Brick.x/2,0,Brick.z/2]) // remove cable end to leave socket
	cube([(Brick.x + 2WallThick – 4Screw[OD]),2Brick.y,2Brick.z],center=true);

	if (End == "Cable")
	translate([-Brick.x/2,0,Brick.z/2]) // remove socket end to leave cable
	cube([(Brick.x + 2WallThick – 4Screw[OD]),2Brick.y,2Brick.z],center=true);

	translate([0,0,Brick.z/2 – Protrusion/2]) // remove power supply brick from interior
	cube(Brick + [0,0,Protrusion],center=true);
	translate([0,0,-Brick.z]) // remove below XY plane
	cube(2*Brick,center=true);

	translate([0,0,Brick.z/2]) // remove AC socket
	rotate([0,-90,0])
	rotate(90)
	linear_extrude(height=Brick.x,convexity=2)
	square(Socket,center=true);

	translate([0,0,Brick.z/2]) // remove DC cable
	rotate([0,90,0])
	rotate(180/8)
	PolyCyl(Cable[OD],Brick.x,8);
	translate([Brick.x/2,0,Brick.z/4 – Protrusion/2]) // … and wire slot
	cube([Brick.x,Cable[ID],Brick.z/2 + Protrusion],center=true);
	}

	}

	//———————-
	// Build it

	if (Layout == "Show")
	BrickMount("Both");

	if (Layout == "Build") {
	translate([5,0,Brick.x/2 + WallThick])
	rotate([0,90,0])
	BrickMount("Cable");
	translate([-5,0,Brick.x/2 + WallThick])
	rotate([0,-90,0])
	BrickMount("Socket");
	}

view raw Power Supply Brick Mount.scad hosted with ❤ by GitHub

The New Hotness

MPCNC: Power Supply Brick Mount