Tag: M2

Using and tweaking a Makergear M2 3D printer

Makergear M2 Extruder Motor Debugging

While sorting out an extrusion problem on the Makergear forum, I suggested marking the motor shaft and the filament drive shaft to see if the motor pinion inside the gearbox had worn out: if the motor turns and the filament gear doesn’t, then it’s dead inside.

For future reference, you mark the motor shaft thusly:

Makergear M2 – filament drive motor – rear shaft

Two marks on the filament drive gear tell you if the shaft is turning and if the gear is slipping on the shaft:

Makergear M2 – filament drive gear

A closeup of an earlier, much coarser, drive gear:

M2 – Filament Drive Gear

It all worked out well in the end!

2020-07-09
Garden Soaker Hose Repairs In Use

Just for completeness, here’s what the various soaker hose clamps look like in the garden, as solid models only let you visualize the ideal situation:

Soaker Hose Connector Clamp – Show view

This one prevents a puddle in the path to the right:

Soaker hose repairs in situ – clamp

Bending the hoses around the end of a bed puts them on edge, with this clamp suppressing a shin-soaking spray to the left:

Soaker hose repairs in situ – end-on clamp

The clamp at the connector closes a leak around the crimped brass fitting, with the other two preventing gouges from direct sprays into the path along the bottom of the picture:

Soaker hose repairs in situ – clamps and connector fix

All in all, a definite UI improvement!

As far as I can tell, we have the only soaker hose repairs & spritz stoppers in existence. Hooray for 3D printing!

2020-07-05
Solid Modeling: Support Puzzle
I’ve been putting this type of support structure inside screw holes & suchlike for years:

Browning Hi-Power Magazine Block – solid model – Generic 1 – support detail

It’s basically a group of small rectangles rotated around the hole’s axis and about one thread thickness shorter than the overhanging interior.

I’ve found that incorporating exactly the right support structure eliminates Slic3r’s weird growths, eases removal, and generally works better all around.

So doing this for the baseplate of the Glass Tile frame came naturally:

Glass Tile Frame – octagonal support

This OpenSCAD snippet plunks one of those asterisks in each of four screw holes:
```
  if (Support)
    color("Yellow")
      for (i=[-1,1], j=[-1,1])
        translate([i*InsertOC.x/2,j*InsertOC.y/2,0])
          for (a=[0:45:135])
              rotate(a)
                translate([0,0,(Screw[LENGTH] - ThreadThick)/2])
                  cube([Screw[OD] - 2*ThreadWidth,2*ThreadWidth,Screw[LENGTH] - ThreadThick],center=true);
```
The “cubes” overlap in the middle, with no completely coincident faces or common edges, so it’s 2-manifold. Slic3r, however, produces a weird time estimate whenever the model includes those structures:

Slic3r – NaN time estimate

NaN stands for Not A Number and means something horrible has happened in the G-Code generation. Fortunately, the G-Code worked perfectly and produced the desired result, but I’m always uneasy when Something Seems Wrong.

Messing around with the code produced a slightly different support structure:

Glass Tile Frame – quad support

The one thread thick square on the bottom helps glue the structure to the platform and four ribs work just as well as eight in the octagonal hole:
```
  Fin = [Screw[OD]/2 - 1.5*ThreadWidth,2*ThreadWidth,ScrewRecess - ThreadThick];
  if (Inserts && SupportInserts)
    color("Yellow")
      for (i=[-1,1], j=[-1,1])
        translate([i*InsertOC.x/2,j*InsertOC.y/2,0]) {
          rotate(180/8)
            cylinder(d=6*ThreadWidth,h=ThreadThick,$fn=8);
          for (a=[0:90:360])
              rotate(a)
                translate([Fin.x/2 + ThreadWidth/2,0,(ScrewRecess - ThreadThick)/2])
                  cube(Fin,center=true);
        }
```
Which changed the NaN time estimates into actual numbers.

One key difference may be the small hole in the middle. The four ribs (not two!) now overlap by one thread width around the hole, so they’re not quite coincident and Slic3r produces a tidy model:

Glass Tile Frame – quad support – Slic3r

The hole eliminates a smear of infill from the center, which may have something to do with the improvement.

In any event, I have an improved copypasta recipe for the next screw holes in need of support, even if I don’t understand why it’s better.
2020-06-12

Glass Tiles: Matrix for SK6812 PCBs

Tweaking the glass tile frame for press-fit SK6812 PCBs in the bottom of the array cells:

Glass Tile Frame - cell array - openscad — Glass Tile Frame – cell array – openscad

Which looks like this with the LEDs and brass inserts installed:

Glass Tile - 2x2 array - interior — Glass Tile – 2×2 array – interior

The base holds an Arduino Nano with room for wiring under the cell array:

Glass Tile Frame - base - openscad — Glass Tile Frame – base – openscad

Which looks like this after it’s all wired up:

Glass Tile - 2x2 array - wiring — Glass Tile – 2×2 array – wiring

The weird colors showing through the inserts are from the LEDs. The red thing in the upper left is a silicone insulation snippet. Yes, that’s hot-melt glue holding the Arduino Nano in place and preventing the PCBs from getting frisky.

Soak a handful of glass tiles overnight in paint stripper:

Glass Tiles - paint stripper soak — Glass Tiles – paint stripper soak

Whereupon the adhesive slides right off with the gentle application of a razor scraper. Rinse carefully, dry thoroughly, and snap into place.

Tighten the four M3 SHCS and it’s all good:

Glass Tile - 2x2 array - operating — Glass Tile – 2×2 array – operating

So far, I’ve had two people tell me they don’t know what it is, but they want one:

Glass Tile - various versions — Glass Tile – various versions

The OpenSCAD Customizer lets you set the array size:

Glass Tile Frame - 3x3 - press-fit SK6812 LEDs — Glass Tile Frame – 3×3 – press-fit SK6812 LEDs

However, just because you can do something doesn’t mean you should:

Glass Tile Frame - 6x6 cell array - openscad — Glass Tile Frame – 6×6 cell array – openscad

Something like this might be interesting:

Glass Tile Frame - 2x6 cell array - openscad — Glass Tile Frame – 2×6 cell array – openscad

In round numbers, printing the frame takes about an hour per cell, so a 2×2 array takes three hours and 3×3 array runs around seven hours. A 6×6 frame is just not happening.

The OpenSCAD source code as a GitHub Gist:

	// Illuminated Tile Grid
	// Ed Nisley – KE4ZNU
	// 2020-05

	/* [Configuration] */

	Layout = "Build"; // [Cell,CellArray,MCU,Base,Show,Build]

	Shape = "Square"; // [Square, Pyramid, Cone]

	Cells = [2,2];

	CellDepth = 15.0;

	Inserts = true;

	SupportInserts = true;

	/* [Hidden] */

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

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

	Protrusion = 0.1; // make holes end cleanly

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

	Tile = [25.0 + 0.1,25.0 + 0.1,4.0];

	WallThick = 4*ThreadWidth;
	FloorThick = 3.0;

	Flange = [2ThreadWidth,2ThreadWidth,0]; // ridge supporting tile

	Separator = [3ThreadWidth,3ThreadWidth,Tile.z – 1]; // between tiles

	Screw = [3.0,6.0,3.5]; // M3 SHCS, OD=head, LENGTH=head
	Insert = [3.0,4.2,8.0]; // threaded brass insert

	ScrewRecess = Screw[LENGTH] + 4*ThreadThick;

	LEDPCB = [9.6,9.6,2.9]; // round SK6812, squared-off sides

	LED = [5.0 + 2HoleWindage,5.0 + 2HoleWindage,1.3];

	LEDOffset = [0.0,0.0,0.0]; // if offset from PCB center

	CellOAL = [Tile.x,Tile.y,0] + Separator + [0,0,CellDepth] + [0,0,FloorThick];

	ArrayOAL = [Cells.xCellOAL.x,Cells.yCellOAL.y,CellOAL.z]; // just the LED cells

	BlockOAL = ArrayOAL + [2WallThick,2WallThick,0]; // LED cells + exterior wall
	echo(str("Block OAL: ",BlockOAL));

	InsertOC = ArrayOAL – [Insert[OD],Insert[OD],0] – [WallThick,WallThick,0];
	echo(str("Insert OC: ",InsertOC));

	TapeThick = 1.0;

	Arduino = [44.0,18.0,8.0 + TapeThick]; // Arduino Nano to top of USB Mini-B plug
	USBPlug = [15.0,11.0,9.0]; // USB Mini-B plug insulator
	USBOffset = [0,0,5.0]; // offset from PCB base

	WiringSpace = 3.5;
	WiringBay = [(Cells.x – 1)CellOAL.x + LEDPCB.x,(Cells.y – 1)CellOAL.y + LEDPCB.x,WiringSpace];

	PlateOAL = [BlockOAL.x,BlockOAL.y,FloorThick + Arduino.z + WiringSpace]; // allow wiring above Arduino
	echo(str("Base Plate: ",PlateOAL));

	echo(str("Screw length: ",(PlateOAL.z – ScrewRecess) + Insert.z/2," to ",(PlateOAL.z – ScrewRecess) + Insert.z));

	LegendRecess = 1*ThreadThick;

	//————————

	module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
	Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
	FixDia = Dia / cos(180/Sides);
	cylinder(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
	}


	//———————–
	// Base and optics in single tile

	module LEDCone() {

	hull() {
	translate([0,0,CellDepth + Tile.z/2])
	cube(Tile – 2*[Flange.x,Flange.y,0],center=true);

	if (Shape == "Square") {
	translate([0,0,LEDPCB.z/2])
	cube([Tile.x,Tile.y,LEDPCB.z] – 2*[Flange.x,Flange.y,0],center=true);
	}
	else if (Shape == "Pyramid") {
	translate([0,0,LEDPCB.z/2])
	cube(LEDPCB,center=true);
	}
	else if (Shape == "Cone") {
	translate([0,0,LEDPCB.z/2])
	cylinder(d=1.0*LEDPCB.x,h=LED.z,center=true);
	}
	else {
	echo(str("Whoopsie! Invalid Shape: ",Shape));
	cube(5);
	}
	}
	}

	// One complete LED cell

	module LEDCell() {

	difference() {

	translate([0,0,CellOAL.z/2])
	cube(CellOAL + [Protrusion,Protrusion,0],center=true); // force overlapping adjacent sides!

	translate([0,0,CellOAL.z – Separator.z + Tile.z/2])
	cube(Tile,center=true);

	translate([0,0,LEDPCB.z])
	LEDCone();

	// cube([LED.x,LED.y,CellOAL.z],center=true);

	translate(-LEDOffset + [0,0,-CellOAL.z/2])
	rotate(180/8)
	PolyCyl(LEDPCB.x,CellOAL.z,8);
	}

	}

	// The whole array of cells

	module CellArray() {
	difference() {
	union() {
	translate([CellOAL.x/2 – Cells.xCellOAL.x/2,CellOAL.y/2 – Cells.yCellOAL.y/2,0])
	for (i=[0:Cells.x – 1], j=[0:Cells.y – 1])
	translate([iCellOAL.x,jCellOAL.y,0])
	LEDCell();
	if (Inserts) // bosses
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,0])
	rotate(180/8)
	cylinder(d=Insert[OD] + 2*WallThick,h=Insert[LENGTH],$fn=8);
	}
	if (Inserts) // holes
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,-Protrusion])
	rotate(180/8)
	PolyCyl(Insert[OD],Insert[LENGTH] + FloorThick + Protrusion,8);

	}

	difference() {
	translate([0,0,CellOAL.z/2])
	cube(BlockOAL,center=true);
	translate([0,0,CellOAL.z])
	cube(ArrayOAL + [0,0,2*CellOAL.z],center=true);

	}
	}

	// Arduino bounding box
	// Origin at center bottom of PCB

	module Controller() {
	union() {
	translate([0,0,Arduino.z/2])
	cube(Arduino,center=true);
	translate([Arduino.x/2 – Protrusion,-USBPlug.y/2,USBOffset.z + TapeThick – USBPlug.z/2])
	cube(USBPlug + [Protrusion,0,0],center=false);
	}
	}

	// Baseplate

	module BasePlate() {

	difference() {
	translate([0,0,PlateOAL.z/2])
	cube(PlateOAL,center=true);

	translate([PlateOAL.x/2 – Arduino.x/2 – 2*WallThick,0,FloorThick])
	Controller();

	translate([PlateOAL.x/2 – Arduino.x/2 – 2*WallThick,0,FloorThick + PlateOAL.z/2])
	cube([Arduino.x – 2*2.0,WiringBay.y,PlateOAL.z],center=true); // cutouts beside MCU

	translate([0,0,PlateOAL.z – WiringBay.z + PlateOAL.z/2 – Protrusion])
	cube([PlateOAL.x – 2*WallThick,WiringBay.y,PlateOAL.z],center=true); // cutout above MCU
	translate([0,0,PlateOAL.z – WiringBay.z + PlateOAL.z/2 – Protrusion])
	cube([WiringBay.x,PlateOAL.y – 2*WallThick,PlateOAL.z],center=true); // cutout above MCU


	if (Inserts)
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,-Protrusion])
	rotate(180/8) {
	PolyCyl(Screw[ID],2*PlateOAL.z,8);
	PolyCyl(Screw[OD],ScrewRecess + Protrusion,8);
	}

	cube([45,17.0,2*LegendRecess],center=true);
	}

	linear_extrude(height=2*LegendRecess) {
	translate([0,1])
	rotate(-0*90) mirror([1,0,0])
	text(text="Ed Nisley",size=6,font="Arial:style:Bold",halign="center");
	translate([0,-6.5])
	rotate(-0*90) mirror([1,0,0])
	text(text="softsolder.com",size=4.5,font="Arial:style:Bold",halign="center");
	}

	Fin = [Screw[OD]/2 – 1.5ThreadWidth,2ThreadWidth,ScrewRecess – ThreadThick];
	if (Inserts && SupportInserts)
	color("Yellow")
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,0]) {
	rotate(180/8)
	cylinder(d=6*ThreadWidth,h=ThreadThick,$fn=8);
	for (a=[0:90:360])
	rotate(a)
	translate([Fin.x/2 + ThreadWidth/2,0,(ScrewRecess – ThreadThick)/2])
	cube(Fin,center=true);
	}
	}


	//———————–
	// Build things

	if (Layout == "Cell")
	LEDCell();

	else if (Layout == "CellArray")
	CellArray();

	else if (Layout == "MCU")
	Controller();

	else if (Layout == "Base")
	BasePlate();

	else if (Layout == "Show") {
	translate([0,0,3*PlateOAL.z])
	CellArray();
	BasePlate();
	translate([PlateOAL.x/2 – Arduino.x/2 – 2*WallThick,0,FloorThick])
	color("Orange",0.3)
	Controller();
	}

	else if (Layout == "Build") union() {
	translate([0,0.6*BlockOAL.y,0])
	CellArray();
	translate([0,-0.6*BlockOAL.x,0])
	rotate(90)
	BasePlate();
	}

view raw Glass Tile Frame.scad hosted with ❤ by GitHub

2020-06-11

Garden Hose Valve Wrench: Reinforced

After five gardening seasons, my simple 3D printed wrench broke:

Hose Valve Knob - fractured — Hose Valve Knob – fractured

Although Jason’s comment suggesting carbon-fiber reinforcing rods didn’t prompt me to lay in a stock, ordinary music wire should serve the same purpose:

Hose Valve Knob - cut pins — Hose Valve Knob – cut pins

The pins are 1.6 mm diameter and 20 mm long, chopped off with hardened diagonal cutters. Next time, I must (remember to) grind the ends flat.

The solid model needs holes in appropriate spots:

Hose Valve Knob - Reinforced - Slic3r — Hose Valve Knob – Reinforced – Slic3r

Yes, I’m going to put round pins in square holes, without drilling the holes to the proper diameter: no epoxy, no adhesive, just 20 mm of pure friction.

The drill press aligns the pins:

Hose Valve Knob - pin ready — Hose Valve Knob – pin ready

And rams them about halfway down:

Hose Valve Knob - pin midway — Hose Valve Knob – pin midway

Close the chuck jaws and shove them flush with the surface:

Hose Valve Knob - pins installed — Hose Valve Knob – pins installed

You can see the pins and their solid plastic shells through the wrench stem:

Hose Valve Knob - assembled — Hose Valve Knob – assembled

Early testing shows the reinforced wrench works just as well as the previous version, even on some new valves sporting different handles, with an equally sloppy fit for all. No surprise: I just poked holes in the existing model and left all the other dimensions alone.

The OpenSCAD source code as a GitHub Gist:

	// Hose connector knob
	// Ed Nisley KE4ZNU – June 2015
	// 2020-05 add reinforcing rods

	Layout = "Build"; // [Knob, Stem, Show, Build]

	RodHoles = true;

	//- Extrusion parameters – must match reality!

	/* [Hidden] */

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

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

	Protrusion = 0.1;

	HoleWindage = 0.2;

	//——
	// Dimensions

	/* [Dimensions] */

	RodOD = 1.6;
	RodAngle = 35;

	/* [Hidden] */

	StemOD = 30.0; // max OD for valve-to-valve clearance

	BossOD = 16.0; // single-ended handle boss

	SlotWidth = 13.0;
	SlotHeight = 10.0;

	StemInset = 10.0;
	StemLength = StemInset + SlotHeight + 25.0;
	StemSides = 2*4;

	Align = 0180/StemSides; // 1 produces thinner jaw ends

	KnobOD1 = 70; // maximum dia without chamfer
	KnobOD2 = 60; // top dia

	KnobSides = 4*4;

	DomeHeight = 12; // dome shape above lobes

	KnobHeight = DomeHeight + 2*SlotHeight;

	DomeOD = KnobOD2 + (KnobOD1 – KnobOD2)*(DomeHeight/KnobHeight);

	DomeArcRad = (pow(KnobHeight,2) + pow(DomeOD,2)/4) / (2*DomeHeight);

	RodBCD = (StemOD + BossOD)/2;

	//- Adjust hole diameter to make the size come out right

	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);
	}

	//– Stem for valve handles

	module Stem() {

	difference() {
	rotate(Align)
	cylinder(d=StemOD,h=StemLength,$fn=StemSides);
	translate([0,0,SlotHeight/2 – Protrusion/2])
	cube([2*StemOD,SlotWidth,(SlotHeight + Protrusion)],center=true);
	translate([0,0,-Protrusion])
	cylinder(d=BossOD,h=SlotHeight,$fn=2*StemSides);
	if (RodHoles)
	for (i=[-1:1])
	rotate(i*RodAngle + 90)
	for (j=[-1,1])
	translate([j*RodBCD/2,0,-Protrusion])
	rotate(180/4)
	PolyCyl(RodOD,2*SlotHeight,4);
	}

	}


	//– Hand-friendly knob

	module KnobCap() {
	difference() {
	scale([1.0,0.75,1.0])
	rotate(180/KnobSides)
	intersection() {
	translate([0,0,(KnobHeight-DomeArcRad)])
	sphere(r=DomeArcRad,$fa=180/KnobSides);
	cylinder(r1=KnobOD1/2,r2=KnobOD2/2,h=KnobHeight,$fn=KnobSides);
	cylinder(r1=KnobOD2/2,r2=KnobOD1/2,h=KnobHeight,$fn=KnobSides);
	}
	translate([0,0,-Protrusion])
	rotate(Align)
	cylinder(d=(StemOD + 2*ThreadWidth),h=(StemInset + Protrusion),$fn=StemSides);
	}
	}

	//- Build it


	if (Layout == "Knob")
	KnobCap();

	if (Layout == "Stem")
	Stem();

	if (Layout == "Build") {
	translate([-KnobOD1/2,0,0])
	KnobCap();
	translate([StemOD/2,0,StemLength])
	rotate([180,0,0])
	Stem();
	}

	if (Layout == "Show") {
	translate([0,0,0])
	Stem();
	translate([0,0,StemLength – StemInset])
	KnobCap();
	}

view raw Hose Connector Knob.scad hosted with ❤ by GitHub

2020-06-02

Soaker Hose End Plug

One of the soaker hoses in Mary’s Vassar Farms garden split lengthwise near one end:

Soaker Hose Plug - hose split — Soaker Hose Plug – hose split

Although the hose is fully depreciated, I thought it’d be worthwhile to cut off the damaged end and conjure an end cap to see if a simple plug can withstand 100 psi water pressure.

A pair of Delrin (because I have it) plugs with serrations fill the hose channels, with the outer clamp squishing the hose against them:

Soaker Hose Plug - channel plugs - side view — Soaker Hose Plug – channel plugs – side view

In real life, they’ll be pushed completely into the hose, with a generous layer of silicone ~~snot~~ caulk improving their griptivity.

I started with 8 mm plugs, but they didn’t quite fill the channels:

Soaker Hose Plug - channel plugs - 8 mm test fit — Soaker Hose Plug – channel plugs – 8 mm test fit

Going to 8.5 mm worked better, although there’s really no way to force the granulated rubber shape into a snug fit around a cylinder:

Soaker Hose Plug - channel plugs test fit — Soaker Hose Plug – channel plugs test fit

Fortunately, they need not be leakproof, because leaking is what the hose does for a living. Well, did for a living, back before it died.

The clamps have a solid endstop, although it’s more to tidy the end than to hold the plugs in place:

Soaker Hose End Plug - Slic3r — Soaker Hose End Plug – Slic3r

The clamps need aluminum backing plates to distribute the stress evenly across their flat sides:

Soaker Hose Plug - installed — Soaker Hose Plug – installed

Those are 8-32 stainless steel screws. The standard 1 inch length worked out exactly right through no fault of my own.

The OpenSCAD source code as a GitHub Gist:

	// Rubber Soaker Hose End Plug
	// Ed Nisley KE4ZNU June 2019
	// 2020-05 Two-channel hose end plug

	Layout = "Hose"; // [Hose,Block,Show,Build]

	//- Extrusion parameters must match reality!

	/* [Hidden] */

	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
	// Hose lies along X axis

	HoseTubeOD = 12.0; // water tube diameter
	HoseTubeOC = 12.5; // .. spacing
	HoseWebThick = 7.8; // center joining tubes

	Hose = [100,25.0,HoseTubeOD]; // X=very long, Y=overall width, Z=thickness
	HoseSides = 12*4;

	PlugLength = 25.0; // plugs in hose channels

	PlateThick = 5.0; // end block thickness

	WallThick = 2.0; // overall minimum thickness

	Kerf = 0.75; // cut through middle to apply compression

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

	// 8-32 stainless screws
	Screw = [4.1,8.0,3.0]; // OD = head LENGTH = head thickness
	Washer = [4.4,9.5,1.0];
	Nut = [4.1,9.7,6.0];

	CornerRadius = Washer[OD]/2;

	ScrewOC = Hose.y + Washer[OD];

	echo(str("Screw OC: ",ScrewOC));

	BlockOAL = [PlugLength + PlateThick,ScrewOC + Washer[OD],2*WallThick + Hose.z]; // overall splice block size
	echo(str("Block: ",BlockOAL));

	//———————-
	// 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(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
	}

	// Hose shape

	module HoseProfile() {

	rotate([0,-90,0])
	translate([0,0,-Hose.x/2])
	linear_extrude(height=Hose.x,convexity=4)
	union() {
	for (j=[-1,1]) // outer channels
	translate([0,j*HoseTubeOC/2])
	circle(d=HoseTubeOD,$fn=HoseSides);
	translate([0,0])
	square([HoseWebThick,HoseTubeOC],center=true);
	}

	}

	// Outside shape of splice Block
	// Z centered on hose rim circles, not overall thickness through center ridge

	module SpliceBlock() {
	difference() {
	hull()
	for (i=[-1,1], j=[-1,1]) // rounded block
	translate([i(BlockOAL.x/2 – CornerRadius),j(BlockOAL.y/2 – CornerRadius),-BlockOAL.z/2])
	cylinder(r=CornerRadius,h=BlockOAL.z,$fn=4*8);
	for (j=[-1,1]) // screw holes
	translate([0,
	j*ScrewOC/2,
	-(BlockOAL.z/2 + Protrusion)])
	PolyCyl(Screw[ID],BlockOAL.z + 2*Protrusion,6);
	cube([2BlockOAL.x,2BlockOAL.y,Kerf],center=true); // slice through center
	}
	}

	// Splice block less hose

	module ShapedBlock() {
	difference() {
	SpliceBlock();
	translate([(-Hose.x/2) + (BlockOAL.x/2) – PlateThick,0,0])
	HoseProfile();
	}
	}



	//———-
	// Build them

	if (Layout == "Hose")
	HoseProfile();

	if (Layout == "Block")
	SpliceBlock();

	if (Layout == "Show") {
	ShapedBlock();
	translate([(-Hose.x/2) + (BlockOAL.x/2) – PlateThick,0,0])
	color("Green",0.25)
	HoseProfile();
	}

	if (Layout == "Build") {
	SliceOffset = 0;
	intersection() {
	translate([SliceOffset,0,BlockOAL.z/4])
	cube([4BlockOAL.x,4BlockOAL.y,BlockOAL.z/2],center=true);
	union() {
	translate([0,0.6*BlockOAL.y,BlockOAL.z/2])
	ShapedBlock();
	translate([0,-0.6*BlockOAL.y,BlockOAL.z/2])
	rotate([0,180,0])
	ShapedBlock();
	}
	}
	}

view raw Soaker Hose End Plug.scad hosted with ❤ by GitHub

The original doodle, with dimensions vaguely related to the final model:

Soaker Hose End Plug - hose dimensions — Soaker Hose End Plug – hose dimensions

There is, as far as I can tell, no standardization of dimensions or shapes across manufacturers, apart from the threaded hose fittings.

2020-05-29

Glass Tiles: 2×2 Matrix

Start with a single cell holding a glass tile over a WS2812 RGB LED:

Glass Tile - 1x1 cell test - purple phase — Glass Tile – 1×1 cell test – purple phase

A bit of OpenSCAD tinkering produces a simple 2×2 array with square interiors as a test piece:

Glass Tile - 2x2 - PETG strings — Glass Tile – 2×2 – PETG strings

The excessive stringing and the booger in the upper-left cell come from absurdly thin infill tucked into the too-thin walls; Slic3r doesn’t (seem to) have a “minimum infill width” setting and it’ll desperately try to fit infill between two nearly adjacent perimeter threads.

The little support spiders under the LED PCB recesses snapped right out, though, so I got that part right:

Glass Tile - 2x2 - support spiders — Glass Tile – 2×2 – support spiders

The perimeter threads around the LED aperture aren’t quite fused, because it was only one layer thick and that’s not enough.

A quick test with two LEDs showed the white PETG let far too much light bleed between the cells, which was no surprise from the single cell test piece.

Fortunately, it’s all parametric, so a bit more tinkering produced a slightly chunkier matrix with a base for an Arduino Nano and M3 threaded brass inserts for the screws holding it together:

Glass Tile Frame - 2x2 - Arduino Nano base - solid model — Glass Tile Frame – 2×2 – Arduino Nano base – solid model

Those two parts require about three hours of printing, much faster than I could produce them by milling pockets into aluminum or black acrylic slabs, and came out with minimal stringing.

A little cleanup, some epoxy work, and a few dabs of solder later:

Glass Tile - 2x2 - Arduino wiring — Glass Tile – 2×2 – Arduino wiring

An initial lamp test showed the white-ish glass tiles aren’t all quite the same color:

Glass Tile - 2x2 - white color variation — Glass Tile – 2×2 – white color variation

I thought it was an LED color variation, too, but the slightly blue tint in the lower left corner followed the tile.

The blurred horizontal strip across the middle is adhesive tape holding the tiles in place; I was reluctant to glue them in before being sure this whole thing would work. A peek into the future, though, shows it’s got potential:

Glass Tile - 2x2 - first two units — Glass Tile – 2×2 – first two units

They do give off a definite Windows logo vibe, don’t they?

The OpenSCAD source code as a GitHub Gist:

	// Illuminated Tile Grid
	// Ed Nisley – KE4ZNU
	// 2020-05

	/* [Configuration] */

	Layout = "Build"; // [Cell,CellArray,MCU,Base,Show,Build]

	Shape = "Square"; // [Square, Pyramid, Cone]

	Cells = [2,2];

	CellDepth = 15.0;

	Support = true;

	Inserts = true;

	/* [Hidden] */

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

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

	Protrusion = 0.1; // make holes end cleanly

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

	Tile = [25.0 + 0.1,25.0 + 0.1,4.0];

	WallThick = 3*ThreadWidth;

	Flange = [4ThreadWidth,4ThreadWidth,0]; // ridge supporting tile

	Separator = [3ThreadWidth,3ThreadWidth,Tile.z – 1]; // between tiles

	Screw = [3.0,6.0,3.5]; // M3 SHCS, OD=head, LENGTH=head
	Insert = [3.0,4.2,8.0]; // threaded brass insert

	PCB = [15.0,8.0,2.5];

	LED = [5.0 + 2HoleWindage,5.0 + 2HoleWindage,1.0];

	LEDOffset = [0.0,(PCB.y – LED.y)/2 – 0.5,0.0]; // slight offset from +Y PCB edge

	CellOAL = [Tile.x,Tile.y,0] + Separator + [0,0,CellDepth] + [0,0,WallThick] + [0,0,PCB.z];

	ArrayOAL = [Cells.xCellOAL.x,Cells.yCellOAL.y,CellOAL.z]; // just the LED cells

	BlockOAL = ArrayOAL + [2WallThick,2WallThick,0]; // LED cells + exterior wall
	echo(str("Block OAL: ",BlockOAL));

	InsertOC = ArrayOAL – [Insert[OD],Insert[OD],0] – [2WallThick,2WallThick,0];
	echo(str("Insert OC: ",InsertOC));

	TapeThick = 1.0;

	Arduino = [44.0,18.0,8.0 + TapeThick]; // Arduino Nano to top of USB Mini-B plug
	USBPlug = [15.0,11.0,8.5]; // USB Mini-B plug insulator
	USBOffset = [0,0,5.5]; // offset from PCB base

	WiringBay = [BlockOAL.x – 4*WallThick,38.0,3.0];
	PlateOAL = [BlockOAL.x,BlockOAL.y,WallThick + Arduino.z + WiringBay.z];
	echo(str("Base Plate: ",PlateOAL));

	//————————

	module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
	Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
	FixDia = Dia / cos(180/Sides);
	cylinder(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
	}


	//———————–
	// Base and optics in single tile

	module LEDCone() {

	hull() {
	translate([0,0,CellDepth + Tile.z/2])
	cube(Tile – [Flange.x,Flange.y,0],center=true);
	if (Shape == "Square") {
	translate([0,0,LED.z/2])
	cube([Tile.x,Tile.y,LED.z] – [Flange.x,Flange.y,0],center=true);
	}
	else if (Shape == "Pyramid") {
	translate([0,0,LED.z/2])
	cube(LED,center=true);
	}
	else if (Shape == "Cone") {
	translate([0,0,LED.z/2])
	cylinder(d=1.5*LED.x,h=LED.z,center=true);
	}
	else {
	echo(str("Whoopsie! Invalid Shape: ",Shape));
	cube(5);
	}
	}
	}

	// One complete LED cell

	module LEDCell() {
	difference() {

	translate([0,0,CellOAL.z/2])
	cube(CellOAL,center=true);

	translate([0,0,CellOAL.z – Separator.z + Tile.z/2])
	cube(Tile,center=true);

	translate([0,0,PCB.z + WallThick])
	LEDCone();

	cube([LED.x,LED.y,CellOAL.z],center=true);

	translate(-LEDOffset + [0,0,PCB.z/2 – Protrusion/2])
	cube(PCB + [0,0,Protrusion],center=true);
	}

	if (Support)
	color("Yellow") render()
	translate(-LEDOffset) {
	// translate([0,0,ThreadThick/2])
	// cube([PCB.x – 2ThreadWidth,PCB.y – 2ThreadWidth,ThreadThick],center=true);
	intersection() {
	translate([0,0,(PCB.z – ThreadThick)/2])
	cube([PCB.x – 2ThreadWidth,PCB.y – 2ThreadWidth,PCB.z – ThreadThick],center=true);
	union() { for (a=[0:22.5:359])
	rotate(a)
	translate([PCB.x/2,0,PCB.z/2])
	cube([PCB.x,2*ThreadWidth,PCB.z],center=true); }
	}
	}
	}

	// The whole array of cells

	module CellArray() {
	difference() {
	union() {
	translate([CellOAL.x/2 – Cells.xCellOAL.x/2,CellOAL.y/2 – Cells.yCellOAL.y/2,0])
	for (i=[0:Cells.x – 1], j=[0:Cells.y – 1])
	translate([iCellOAL.x,jCellOAL.y,0])
	LEDCell();
	if (Inserts) // bosses
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,0])
	rotate(180/8)
	cylinder(d=Insert[OD] + 3*WallThick,h=Insert[LENGTH],$fn=8);
	}
	if (Inserts) // holes
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,-Protrusion])
	rotate(180/8)
	PolyCyl(Insert[OD],Insert[LENGTH] + WallThick + Protrusion,8);

	}

	difference() {
	translate([0,0,CellOAL.z/2])
	cube(BlockOAL,center=true);
	translate([0,0,CellOAL.z])
	cube(ArrayOAL + [0,0,2*CellOAL.z],center=true);

	}
	}

	// Arduino bounding box
	// Origin at center bottom of PCB

	module Controller() {
	union() {
	translate([0,0,Arduino.z/2])
	cube(Arduino,center=true);
	translate([Arduino.x/2 – Protrusion,-USBPlug.y/2,USBOffset.z + TapeThick – USBPlug.z/2])
	cube(USBPlug + [Protrusion,0,0],center=false);
	}
	}

	// Baseplate

	module BasePlate() {

	difference() {
	translate([0,0,PlateOAL.z/2])
	cube(PlateOAL,center=true);
	translate([0,0,WallThick])
	Controller();
	translate([0,0,WallThick + PlateOAL.z/2])
	cube([Arduino.x – 2*2.0,WiringBay.y,PlateOAL.z],center=true);
	translate([0,0,PlateOAL.z – WiringBay.z + WiringBay.z/2])
	cube(WiringBay + [0,0,2*Protrusion],center=true);
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,-Protrusion])
	rotate(180/8) {
	PolyCyl(Screw[ID],2*PlateOAL.z,8);
	PolyCyl(Screw[OD],Screw[LENGTH] + 4*ThreadThick + Protrusion,8);
	}
	translate([0,0,ThreadThick-Protrusion])
	cube([17.0,45,2*ThreadThick],center=true);
	}

	linear_extrude(height=2*ThreadWidth + Protrusion) {
	translate([1,0,-Protrusion])
	rotate(-90) mirror([1,0,0])
	text(text="Ed Nisley",size=6,font="Arial:style:Bold",halign="center");
	translate([-6.5,0,-Protrusion])
	rotate(-90) mirror([1,0,0])
	text(text="softsolder.com",size=4.5,font="Arial:style:Bold",halign="center");
	}

	if (Support)
	color("Yellow")
	for (i=[-1,1], j=[-1,1])
	translate([iInsertOC.x/2,jInsertOC.y/2,0])
	for (a=[0:45:135])
	rotate(a)
	translate([0,0,(Screw[LENGTH] – ThreadThick)/2])
	cube([Screw[OD] – 2ThreadWidth,2ThreadWidth,Screw[LENGTH] – ThreadThick],center=true);
	}


	//———————–
	// Build things

	if (Layout == "Cell")
	LEDCell();

	else if (Layout == "CellArray")
	CellArray();

	else if (Layout == "MCU")
	Controller();

	else if (Layout == "Base")
	BasePlate();

	else if (Layout == "Show") {
	translate([0,0,PlateOAL.z + 10])
	CellArray();
	BasePlate();
	}

	else if (Layout == "Build") {
	translate([0,0.6*BlockOAL.y,0])
	CellArray();
	translate([0,-0.6*BlockOAL.y,0])
	rotate(90)
	BasePlate();
	}

view raw Glass Tile Frame.scad hosted with ❤ by GitHub

2020-05-27

Tag: M2

Makergear M2 Extruder Motor Debugging

Garden Soaker Hose Repairs In Use

Solid Modeling: Support Puzzle

Glass Tiles: Matrix for SK6812 PCBs

Garden Hose Valve Wrench: Reinforced

Soaker Hose End Plug

Glass Tiles: 2×2 Matrix