metric/screw: fix screw head cut diametea

include <system.scad>
include <shapes.scad>
include <transforms.scad>
include <misc.scad>

include <metric-thread-data.scad>
include <metric-hexnut-data.scad>
include <metric-knurlnut-data.scad>

use <scad-utils/transformations.scad>

// naive, assume head height is same as thread size (generally true for cap heads)
function get_screw_head_h(thread) = lookup(ThreadSize, thread);
function get_screw_head_d(thread) = 2 * lookup(ThreadSize, thread);

module screw(nut, thread, h=10, tolerance=1.05, head_embed=false, with_nut=true, with_head=true, nut_offset=0, orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "screw: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "screw: Mismatched nut and thread");*/

    head_h = get_screw_head_h(nut);
    nut_h = lookup(MHexNutThickness,nut)*tolerance;
    threadsize = lookup(ThreadSize, thread_);

    s = threadsize*tolerance;
    total_h = h;
    size_align(size=[s, s, total_h], orient=-orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,head_embed?-head_h:0])
        {
            if(with_head)
            {
                translate([0,0,h/2+.01])
                screw_head(thread=thread_, orient=[0,0,1], align=[0,0,1]);
            }

            screw_thread(thread=thread_, h=h+.1, tolerance=tolerance, orient=[0,0,1], align=[0,0,0]);

            if(with_nut && nut != undef)
            {
                translate([0,0,-h/2+nut_h+nut_offset+(head_embed?head_h:0)])
                screw_nut(nut=nut, tolerance=tolerance, orient=[0,0,1], align=[0,0,-1]);
            }
        }
    }
}

module screw_cut(nut, thread, h=10, tolerance=1.05, head_embed=false, with_nut=true, nut_cut_h=1000, with_head=true, head_cut_h=1000, nut_offset=0, cut_access=true, orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "screw_cut: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "screw_cut: Mismatched nut and thread");*/

    nut_h = get(MHexNutThickness,nut)*tolerance;
    head_h = get_screw_head_h(thread);
    threadsize = get(ThreadSize, thread_);

    s = threadsize*tolerance;
    total_h = h;
    size_align(size=[s, s, total_h], orient=-orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,head_embed?-head_h:0])
        {
            if(with_head)
            {
                translate([0,0,h/2+.01])
                screw_head_cut(thread=thread_, tolerance=tolerance, override_h=head_cut_h, align=[0,0,1]);
            }

            screw_thread_cut(thread=thread_, h=h+.1, tolerance=tolerance, orient=[0,0,1], align=[0,0,0]);

            if(with_nut && nut != undef)
            {
                translate([0,0,-h/2+nut_h+nut_offset+(head_embed?head_h:0)])
                screw_nut_cut(nut=nut, tolerance=tolerance, h=nut_cut_h, align=[0,0,-1]);
            }
        }
    }

    if($show_vit)
    {
        %screw(nut=nut, thread=thread, h=h, tolerance=tolerance, head_embed=head_embed, with_nut=with_nut, with_head=with_head, nut_offset=nut_offset, orient=orient, align=align);
    }
}

module screw_thread(thread, h=10, tolerance=1.00, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_thread: thread is undef");
    // TODO render thread
    threadsize = lookup(ThreadSize, thread);
    cylindera(d=threadsize, h=h, orient=orient, align=align);
}

module screw_thread_cut(thread, h=10, tolerance=1.05, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_thread_cut: thread is undef");
    threadsize = lookup(ThreadSize, thread);
    cylindera(d=threadsize*tolerance, h=h, orient=orient, align=align);
}

module screw_head(thread, tolerance=1.00, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_head: thread is undef");

    threadsize = lookup(ThreadSize, thread);
    head_h = get_screw_head_h(thread);
    head_d = get_screw_head_d(thread);
    size_align(size=[head_d, head_d, head_h], orient=orient, align=align)
    difference()
    {
        cylindera(d=head_d, h = fallback(override_h,head_h));
        translate([0,0,head_h/2])
        cylindera(d=threadsize, h = head_d/2);
    }
}

module screw_head_cut(thread, tolerance=1.05, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_head_cut: thread is undef");

    threadsize = lookup(ThreadSize, thread);
    head_h = get_screw_head_h(thread);
    head_d = get_screw_head_d(thread)*tolerance;
    size_align(size=[head_d, head_d, head_h], orient=orient, align=align)
    translate([0,0,-head_h/2])
    cylindera(d=head_d, h=fallback(override_h, head_h), align=[0,0,1]);
}

module screw_nut(nut, tolerance=1.00, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(nut!=undef, "screw_nut: nut is undef");

    thickness = lookup(MHexNutThickness,nut)*tolerance;
    d = lookup(MHexNutWidthMin, nut)*tolerance;
    facets = lookup(MHexNutFacets, nut);
    cylindera($fn=lookup(MHexNutFacets, nut), d=d, h=fallback(override_h, thickness), orient=orient, align=align);
}

module screw_nut_cut(nut, tolerance=1.05, h=1000, orient=[0,0,1], align=[0,0,0])
{
    assert(nut!=undef, "screw_nut_cut: nut is undef");

    thickness = lookup(MHexNutThickness,nut)*tolerance;
    d = lookup(MHexNutWidthMin, nut)*tolerance;
    size_align(size=[d,d,thickness], orient=orient, align=align)
    {
        translate([0,0,thickness/2])
        {
            screw_nut(nut, tolerance, orient=[0,0,1], align=[0,0,-1]);
            translate([0,0,-thickness+.01])
            {
                cylindera(d=d*1.1, h=h, orient=[0,0,1], align=[0,0,-1]);
            }
        }
    }
}

module nut_trap_cut(nut, thread, trap_offset=10, screw_l=10*mm, screw_l_extra=2*mm, trap_h=10, trap_axis=[0,-1,0], orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "nut_trap_cut: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "nut_trap_cut: Mismatched nut and thread");*/

    threadsize = lookup(ThreadSize, thread_);
    head_h = get_screw_head_h(thread);
    nut_h = lookup(MHexNutThickness,nut)+.5*mm;

    nut_width_min = lookup(MHexNutWidthMin, nut)+.2*mm;
    nut_width_max = lookup(MHexNutWidthMax, nut)+.2*mm;
    s = nut_width_min;
    total_h = nut_h;

    size_align(size=[s, s, total_h], orient=orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,nut_h/2-.1])
        screw_thread_cut(thread=thread_, tolerance=1.1, h=screw_l, orient=[0,0,-1], align=[0,0,1]);

        if(screw_l_extra>0)
        translate([0,0,-nut_h/2+.1])
        screw_thread_cut(thread=thread_, tolerance=1.1, h=screw_l_extra+.1, orient=[0,0,1], align=[0,0,-1]);

        hull()
        {
            orient(-orient)
            stack(dist=trap_h, axis=trap_axis)
            {
                orient(orient)
                cylindera($fn=lookup(MHexNutFacets, nut), d=nut_width_max, h=nut_h, align=[0,0,0]);

                orient(orient)
                cubea(size=[nut_width_min,nut_width_min,nut_h], align=[0,0,0]);
            }
        }

        if($show_vit)
        {
            translate([0,0, screw_l])
            translate([0,0, -nut_h/2])
            %screw(nut=nut, thread=thread, tolerance=1, with_nut=false, orient=[0,0,-1], align=[0,0,-1]);

            %screw_nut(nut=nut, thread=thread, tolerance=1, orient=[0,0,-1], align=[0,0,0]);
        }

    }
}

function get(key, dict) =
    let(x = search(key, dict))
    let(kv = dict[x[0]])
    kv[1];

if(false)
{
    nut1 = MHexNutM3;
    nut2 = MHexNutM5;
    nut3 = MKnurlInsertNutM3_3_42;
    nut4 = MKnurlInsertNutM3_5_42;

    /*translate([0,20,0])*/
    /*translate([0,20,0])*/
    /*for(axis1=[0:len(AXES)-1])*/
    /*[>for(axis2=AXES)<]*/
    /*translate(20*AXES[axis1])*/
    /*{*/
        /*ta = v_rotate(90, AXES[axis1])*AXES[axis1];*/
        /*echo(AXES[axis1], ta);*/
        /*nut_trap_cut(nut=nut1, trap_axis=ta, orient=AXES[axis1]);*/
    /*}*/

    /*stack(d=30, axis=[1,0,0])*/
    /*{*/
        /*stack(d=20, axis=[0,1,0])*/
        /*{*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[1,0,0]);*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[-1,0,0]);*/
        /*}*/

        /*stack(d=20, axis=[1,0,0])*/
        /*{*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[0,1,0]);*/

            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[0,-1,0]);*/
        /*}*/
    /*}*/

    box_w = 100;
    box_h = 10;
    box_d = 10;
    o = 10;

    $show_vit = true;
    $fs= 0.5;
    $fa = 4;

    difference()
    {
        cubea([box_w,box_d/2,box_h], align=[1,1,1]);

        test_cuts();
    }
    /*difference()*/
    /*{*/
        /*cubea([box_w,box_d/2,box_h], align=[1,-1,1]);*/

        /*test_cuts();*/
    /*}*/

}

module test_cuts()
{
    union()
    {
        offset = 0;
        /*offset = -5;*/
        translate([0,offset,0])
        translate([5,0,0])
        stack(dist=10,axis=[1,0,0])
        {
            screw_cut(nut=nut1, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(thread=ThreadM5, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut1, h=box_h, head_embed=false, orient=[0,0,1], align=[0,0,1]);

            screw_cut(nut=nut1, h=box_h*mm, nut_offset=0*mm, head_embed=true, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut2, h=box_h*mm, nut_offset=3*mm, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut3, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut4, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);

            /*translate([0,5,0])*/
            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=5, head_embed=false, trap_h=10, trap_axis=[0,-1,0], orient=[0,0,-1], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=5, head_embed=false, trap_h=10, trap_axis=[0,1,0], orient=[0,0,1], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=box_d, head_embed=false, trap_h=10, screw_l_extra=2*mm, trap_axis=[0,0,1], orient=[0,1,0], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=box_d, head_embed=false, trap_h=10, screw_l_extra=2*mm, trap_axis=[0,0,-1], orient=[0,1,0], align=[0,0,0]);
        }
    }
}

include <system.scad>
include <shapes.scad>
include <transforms.scad>
include <misc.scad>

include <metric-thread-data.scad>
include <metric-hexnut-data.scad>
include <metric-knurlnut-data.scad>

use <scad-utils/transformations.scad>

// naive, assume head height is same as thread size (generally true for cap heads)
function get_screw_head_h(thread) = lookup(ThreadSize, thread);
function get_screw_head_d(thread) = 1.5 * lookup(ThreadSize, thread);

module screw(nut, thread, h=10, tolerance=1.05, head_embed=false, with_nut=true, with_head=true, nut_offset=0, orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "screw: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "screw: Mismatched nut and thread");*/

    head_h = get_screw_head_h(nut);
    nut_h = lookup(MHexNutThickness,nut)*tolerance;
    threadsize = lookup(ThreadSize, thread_);

    s = threadsize*tolerance;
    total_h = h;
    size_align(size=[s, s, total_h], orient=-orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,head_embed?-head_h:0])
        {
            if(with_head)
            {
                translate([0,0,h/2+.01])
                screw_head(thread=thread_, orient=[0,0,1], align=[0,0,1]);
            }

            screw_thread(thread=thread_, h=h+.1, tolerance=tolerance, orient=[0,0,1], align=[0,0,0]);

            if(with_nut && nut != undef)
            {
                translate([0,0,-h/2+nut_h+nut_offset+(head_embed?head_h:0)])
                screw_nut(nut=nut, tolerance=tolerance, orient=[0,0,1], align=[0,0,-1]);
            }
        }
    }
}

module screw_cut(nut, thread, h=10, tolerance=1.05, head_embed=false, with_nut=true, nut_cut_h=1000, with_head=true, head_cut_h=1000, nut_offset=0, cut_access=true, orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "screw_cut: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "screw_cut: Mismatched nut and thread");*/

    nut_h = get(MHexNutThickness,nut)*tolerance;
    head_h = get_screw_head_h(thread);
    threadsize = get(ThreadSize, thread_);

    s = threadsize*tolerance;
    total_h = h;
    size_align(size=[s, s, total_h], orient=-orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,head_embed?-head_h:0])
        {
            if(with_head)
            {
                translate([0,0,h/2+.01])
                screw_head_cut(thread=thread_, tolerance=1.25, override_h=head_cut_h, align=[0,0,1]);
            }

            screw_thread_cut(thread=thread_, h=h+.1, tolerance=tolerance, orient=[0,0,1], align=[0,0,0]);

            if(with_nut && nut != undef)
            {
                translate([0,0,-h/2+nut_h+nut_offset+(head_embed?head_h:0)])
                screw_nut_cut(nut=nut, tolerance=tolerance, h=nut_cut_h, align=[0,0,-1]);
            }
        }
    }

    if($show_vit)
    {
        %screw(nut=nut, thread=thread, h=h, tolerance=tolerance, head_embed=head_embed, with_nut=with_nut, with_head=with_head, nut_offset=nut_offset, orient=orient, align=align);
    }
}

module screw_thread(thread, h=10, tolerance=1.00, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_thread: thread is undef");
    // TODO render thread
    threadsize = lookup(ThreadSize, thread);
    cylindera(d=threadsize, h=h, orient=orient, align=align);
}

module screw_thread_cut(thread, h=10, tolerance=1.05, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_thread_cut: thread is undef");
    threadsize = lookup(ThreadSize, thread);
    cylindera(d=threadsize*tolerance, h=h, orient=orient, align=align);
}

module screw_head(thread, tolerance=1.00, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_head: thread is undef");

    threadsize = lookup(ThreadSize, thread);
    head_h = get_screw_head_h(thread);
    head_d = get_screw_head_d(thread);
    size_align(size=[head_d, head_d, head_h], orient=orient, align=align)
    difference()
    {
        cylindera(d=head_d, h = fallback(override_h,head_h));
        translate([0,0,head_h/2])
        cylindera(d=threadsize, h = head_d/2);
    }
}

module screw_head_cut(thread, tolerance=1.05, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(thread!=undef, "screw_head_cut: thread is undef");

    threadsize = lookup(ThreadSize, thread);
    head_h = get_screw_head_h(thread);
    head_d = get_screw_head_d(thread)*tolerance;
    size_align(size=[head_d, head_d, head_h], orient=orient, align=align)
    translate([0,0,-head_h/2])
    cylindera(d=head_d, h=fallback(override_h, head_h), align=[0,0,1]);
}

module screw_nut(nut, tolerance=1.00, override_h=undef, orient=[0,0,1], align=[0,0,0])
{
    assert(nut!=undef, "screw_nut: nut is undef");

    thickness = lookup(MHexNutThickness,nut)*tolerance;
    d = lookup(MHexNutWidthMin, nut)*tolerance;
    facets = lookup(MHexNutFacets, nut);
    cylindera($fn=lookup(MHexNutFacets, nut), d=d, h=fallback(override_h, thickness), orient=orient, align=align);
}

module screw_nut_cut(nut, tolerance=1.05, h=1000, orient=[0,0,1], align=[0,0,0])
{
    assert(nut!=undef, "screw_nut_cut: nut is undef");

    thickness = lookup(MHexNutThickness,nut)*tolerance;
    d = lookup(MHexNutWidthMin, nut)*tolerance;
    size_align(size=[d,d,thickness], orient=orient, align=align)
    {
        translate([0,0,thickness/2])
        {
            screw_nut(nut, tolerance, orient=[0,0,1], align=[0,0,-1]);
            translate([0,0,-thickness+.01])
            {
                cylindera(d=d*1.1, h=h, orient=[0,0,1], align=[0,0,-1]);
            }
        }
    }
}

module nut_trap_cut(nut, thread, trap_offset=10, screw_l=10*mm, screw_l_extra=2*mm, trap_h=10, trap_axis=[0,-1,0], orient=[0,0,1], align=[0,0,0])
{
    nut_thread = get(MHexNutThread, nut);
    thread_ = fallback(thread, nut_thread);
    assert(thread_ != undef, "nut_trap_cut: No nut or thread given");
    /*assert(nut!=undef && thread!=undef && nut_thread != thread_, "nut_trap_cut: Mismatched nut and thread");*/

    threadsize = lookup(ThreadSize, thread_);
    head_h = get_screw_head_h(thread);
    nut_h = lookup(MHexNutThickness,nut)+.5*mm;

    nut_width_min = lookup(MHexNutWidthMin, nut)+.2*mm;
    nut_width_max = lookup(MHexNutWidthMax, nut)+.2*mm;
    s = nut_width_min;
    total_h = nut_h;

    size_align(size=[s, s, total_h], orient=orient, orient_ref=[0,0,1], align=align)
    {
        translate([0,0,nut_h/2-.1])
        screw_thread_cut(thread=thread_, tolerance=1.1, h=screw_l, orient=[0,0,-1], align=[0,0,1]);

        if(screw_l_extra>0)
        translate([0,0,-nut_h/2+.1])
        screw_thread_cut(thread=thread_, tolerance=1.1, h=screw_l_extra+.1, orient=[0,0,1], align=[0,0,-1]);

        hull()
        {
            orient(-orient)
            stack(dist=trap_h, axis=trap_axis)
            {
                orient(orient)
                cylindera($fn=lookup(MHexNutFacets, nut), d=nut_width_max, h=nut_h, align=[0,0,0]);

                orient(orient)
                cubea(size=[nut_width_min,nut_width_min,nut_h], align=[0,0,0]);
            }
        }

        if($show_vit)
        {
            translate([0,0, screw_l])
            translate([0,0, -nut_h/2])
            %screw(nut=nut, thread=thread, tolerance=1, with_nut=false, orient=[0,0,-1], align=[0,0,-1]);

            %screw_nut(nut=nut, thread=thread, tolerance=1, orient=[0,0,-1], align=[0,0,0]);
        }

    }
}

function get(key, dict) =
    let(x = search(key, dict))
    let(kv = dict[x[0]])
    kv[1];

if(false)
{
    nut1 = MHexNutM3;
    nut2 = MHexNutM5;
    nut3 = MKnurlInsertNutM3_3_42;
    nut4 = MKnurlInsertNutM3_5_42;

    /*translate([0,20,0])*/
    /*translate([0,20,0])*/
    /*for(axis1=[0:len(AXES)-1])*/
    /*[>for(axis2=AXES)<]*/
    /*translate(20*AXES[axis1])*/
    /*{*/
        /*ta = v_rotate(90, AXES[axis1])*AXES[axis1];*/
        /*echo(AXES[axis1], ta);*/
        /*nut_trap_cut(nut=nut1, trap_axis=ta, orient=AXES[axis1]);*/
    /*}*/

    /*stack(d=30, axis=[1,0,0])*/
    /*{*/
        /*stack(d=20, axis=[0,1,0])*/
        /*{*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[1,0,0]);*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[-1,0,0]);*/
        /*}*/

        /*stack(d=20, axis=[1,0,0])*/
        /*{*/
            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[0,1,0]);*/

            /*nut_trap_cut(nut=nut1, trap_axis=[0,0,1], orient=[0,-1,0]);*/
        /*}*/
    /*}*/

    box_w = 100;
    box_h = 10;
    box_d = 10;
    o = 10;

    $show_vit = true;
    $fs= 0.5;
    $fa = 4;

    difference()
    {
        cubea([box_w,box_d/2,box_h], align=[1,1,1]);

        test_cuts();
    }
    /*difference()*/
    /*{*/
        /*cubea([box_w,box_d/2,box_h], align=[1,-1,1]);*/

        /*test_cuts();*/
    /*}*/

}

module test_cuts()
{
    union()
    {
        offset = 0;
        /*offset = -5;*/
        translate([0,offset,0])
        translate([5,0,0])
        stack(dist=10,axis=[1,0,0])
        {
            screw_cut(nut=nut1, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(thread=ThreadM5, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut1, h=box_h, head_embed=false, orient=[0,0,1], align=[0,0,1]);

            screw_cut(nut=nut1, h=box_h*mm, nut_offset=0*mm, head_embed=true, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut2, h=box_h*mm, nut_offset=3*mm, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut3, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);
            screw_cut(nut=nut4, h=box_h, head_embed=false, orient=[0,0,-1], align=[0,0,1]);

            /*translate([0,5,0])*/
            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=5, head_embed=false, trap_h=10, trap_axis=[0,-1,0], orient=[0,0,-1], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=5, head_embed=false, trap_h=10, trap_axis=[0,1,0], orient=[0,0,1], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=box_d, head_embed=false, trap_h=10, screw_l_extra=2*mm, trap_axis=[0,0,1], orient=[0,1,0], align=[0,0,0]);

            translate([0,0,box_h/2])
                nut_trap_cut(nut=nut1, h=box_d, head_embed=false, trap_h=10, screw_l_extra=2*mm, trap_axis=[0,0,-1], orient=[0,1,0], align=[0,0,0]);
        }
    }
}


Round edges of part below fan; correct two profiles which were supposed to  line up.

/* Orientation is that "up" faces into the heatsink. */
module Spacer(w=40,r=2,thick=9) {
    difference() {
        hull()
        for(x=[w/2-r,w/2-8+r])
            for(y=[r,9-r])
                translate([x,y]) cylinder(r=r,h=thick);
    }
}

module SpacerHole(thick=9) {
    translate([16,4.5,-1]) cylinder(d=3.4,h=thick+2);
}

module LowerHull(w,r,thick,d=0) {
    hull() {
        for(x=[w/2-r-d,-(w/2-r-d)])
            translate([x,r-d]) cylinder(r=r,h=thick);
        for(x=[w/2-8-r,-(w/2-8-r)])
            translate([x,-8+r]) cylinder(r=r,h=thick);
    }
}

module SpacerMount(w=40,r=2,thick=9) {
    difference() {
        LowerHull(w,2,thick);
        hull() {
            for(x=[w/2-7-r,-(w/2-7-r)])
                for(y=[r+0.01,r*2])
                    translate([x,y,-1]) cylinder(r=r,h=thick+2);
        }
        hull() {
            for(y=[-r-1,-10])
            translate([0,y,thick])
            rotate([0,90,0]) cylinder(r=2,h=100,center=true);
        }
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([6,-4.5,-1]) union() {
                cylinder(d=3.4,h=100);
                translate([0,0,thick-3]) cylinder(d=5.6,h=100);
            }
    }
}

module SpacerPair() {
    difference() {
        union() {
            Spacer($fn=32);
            scale([-1,1,1]) Spacer($fn=32);
            translate([-38/2,1.32,0]) cube([38,1.7,8]);
            SpacerMount($fn=32);
        }
        SpacerHole($fn=32);
        scale([-1,1,1]) SpacerHole($fn=32);
    }
}

module ThinCylinder(r,h,t) {
    difference() {
        cylinder(r=r,h=h);
        translate([0,0,-1]) cylinder(r=r-t,h=h+2);
    }
}

module FanGrill(r,spacing1=1.6,spacing2=8,height=3) {
    translate([0,0,-0.01]) difference() {
        cylinder(r=r,h=100);
        rotate([0,0,45]) cube([spacing1,100,height*2],center=true);
        rotate([0,0,-45]) cube([spacing1,100,height*2],center=true);
        for(x=[2.5:spacing2:r]) {
            ThinCylinder(x,height,spacing1);
        }
    }
}

module ChamferCylinder(r,h,c=2) {
    cylinder(r=r,h=h-c);
    translate([0,0,h-c]) cylinder(r1=r,r2=r-c,h=c);
}

module FanMount(w=40,r=4,thick=3) {
    // Bottom flat part
    difference() {
        union() {
            hull() {
                for(x_scale=[1,-1])
                    for(y_scale=[1,-1])
                        scale([x_scale,y_scale,1])
                        translate([w/2-r,w/2-r])
                        cylinder(r=r,h=thick);
                translate([0,-20,0]) LowerHull(w,2,thick);
            }
            for(x_scale=[1,-1])
                for(y_scale=[1,-1])
                scale([x_scale,y_scale,1])
                translate([16,16,0.01]) ChamferCylinder(5.6/2,thick+3.5,0.6);
        }
        FanGrill(r=16,height=thick-1);
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([16,-16,-0.01]) cylinder(d=3.4,h=100);
    }
    // Top part
    difference() {
        translate([0,-20,0]) LowerHull(w,2,thick+11,4);
        //cube([40,40,40],center=true);
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([6,-20-4.5,-1]) cylinder(d=2.9,h=100);
    }
}

/* For printing */
translate([0,-40,0]) SpacerPair();
/* Assembly */
//translate([0,-20,12]) SpacerPair();
FanMount($fn=64);

/*
projection(cut=false) rotate([0,90,0]) {
translate([0,-20,12]) SpacerPair();
FanMount($fn=64);
}
*/

/* Orientation is that "up" faces into the heatsink. */
module Spacer(w=40,r=2,thick=9) {
    difference() {
        hull()
        for(x=[w/2-r,w/2-8+r])
            for(y=[r,9-r])
                translate([x,y]) cylinder(r=r,h=thick);
    }
}

module SpacerHole(thick=9) {
    translate([16,4.5,-1]) cylinder(d=3.4,h=thick+2);
}

module LowerHull(w,r,thick) {
    hull() {
        for(x=[w/2-r,-(w/2-r)])
            translate([x,r]) cylinder(r=r,h=thick);
        for(x=[w/2-8-r,-(w/2-8-r)])
            translate([x,-8+r]) cylinder(r=r,h=thick);
    }
}

module SpacerMount(w=40,r=2,thick=9) {
    difference() {
        LowerHull(w,r,thick);
        hull() {
            for(x=[w/2-7-r,-(w/2-7-r)])
                for(y=[r+0.01,r*2])
                    translate([x,y,-1]) cylinder(r=r,h=thick+2);
        }
        hull() {
            for(y=[-r-1,-10])
            translate([0,y,thick])
            rotate([0,90,0]) cylinder(r=2,h=100,center=true);
        }
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([6,-4.5,-1]) union() {
                cylinder(d=3.4,h=100);
                translate([0,0,thick-3]) cylinder(d=5.6,h=100);
            }
    }
}

module SpacerPair() {
    difference() {
        union() {
            Spacer($fn=32);
            scale([-1,1,1]) Spacer($fn=32);
            translate([-38/2,1.32,0]) cube([38,1.7,8]);
            SpacerMount($fn=32);
        }
        SpacerHole($fn=32);
        scale([-1,1,1]) SpacerHole($fn=32);
    }
}

translate([0,-40,0]) SpacerPair();

module ThinCylinder(r,h,t) {
    difference() {
        cylinder(r=r,h=h);
        translate([0,0,-1]) cylinder(r=r-t,h=h+2);
    }
}

module FanGrill(r,spacing1=1.6,spacing2=8,height=3) {
    translate([0,0,-0.01]) difference() {
        cylinder(r=r,h=100);
        rotate([0,0,45]) cube([spacing1,100,height*2],center=true);
        rotate([0,0,-45]) cube([spacing1,100,height*2],center=true);
        for(x=[2.5:spacing2:r]) {
            ThinCylinder(x,height,spacing1);
        }
    }
}

module ChamferCylinder(r,h,c=2) {
    cylinder(r=r,h=h-c);
    translate([0,0,h-c]) cylinder(r1=r,r2=r-c,h=c);
}

module FanMount(w=40,r=4,thick=3) {
    difference() {
        union() {
            hull() {
                for(x_scale=[1,-1])
                    for(y_scale=[1,-1])
                        scale([x_scale,y_scale,1])
                        translate([w/2-r,w/2-r])
                        cylinder(r=r,h=thick);
                translate([0,-20,0]) LowerHull(w,r,thick);
            }
            for(x_scale=[1,-1])
                for(y_scale=[1,-1])
                scale([x_scale,y_scale,1])
                translate([16,16,0.01]) ChamferCylinder(5.6/2,thick+3.5,0.6);
        }
        FanGrill(r=16,height=thick-1);
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([16,-16,-0.01]) cylinder(d=3.4,h=100);
    }
    difference() {
        translate([0,-20,0]) LowerHull(w,r,thick+11);
        cube([40,40,40],center=true);
        for(x_scale=[1,-1])
            scale([x_scale,1,1])
            translate([6,-20-4.5,-1]) cylinder(d=2.9,h=100);
    }
}

FanMount($fn=64);


[scad] add ring magnet snap-to-fit

[scad] add ring magnet snap-to-fit


Added new BG10 X/Y idlers to better fit metal, toothed, flanged idler; also .5mm taller to allow less movement.


shapes: add roll param to cube

shapes: add roll param to cube

include <system.scad>
include <units.scad>
use <misc.scad>
use <transforms.scad>

module cubea(size=[10,10,10], align=[0,0,0], extrasize=[0,0,0], extrasize_align=[0,0,0], orient=[0,0,1], roll=0)
{
    size_align(size=size,extra_size=extrasize, align=align, extra_align=extrasize_align, orient=orient, orient_ref=[0,0,1], roll=roll)
    {
        cube(size+extrasize, center=true);
    }
}

module rcubea(size=[10,10,10], rounding_radius=1, align=[0,0,0], extrasize=[0,0,0], extrasize_align=[0,0,0], orient=[0,0,1], roll=0)
{
    size_align(size=size,extra_size=extrasize, align=align, extra_align=extrasize_align, orient=orient, orient_ref=[0,0,1], roll=roll)
    {
        rcube(size=size+extrasize, rounding_radius=rounding_radius);
    }
}

module rcube(size=[20,20,20], rounding_radius=1)
{
    hull()
    for(x=[-(size[0]/2-rounding_radius),(size[0]/2-rounding_radius)])
    for(y=[-(size[1]/2-rounding_radius),(size[1]/2-rounding_radius)])
    for(z=[-(size[2]/2-rounding_radius),(size[2]/2-rounding_radius)])
    translate([x,y,z])
    sphere(r=rounding_radius);
}

module cylindera(
        h=10,
        r=undef,
        r1=undef,
        r2=undef,
        d=undef,
        d1=undef,
        d2=undef,
        align=[0,0,0],
        orient=[0,0,1],
        extra_h=0,
        extra_r=undef,
        extra_d=undef,
        extra_align=[0,0,0],
        round_radius=undef,
        debug=false
        )
{
    pi=3.1415926536;

    useDia = r == undef && (r1 == undef && r2 == undef);

    r1_ = useDia?((d1==undef?undef:d1)/2):r1;
    r2_ = useDia?((d2==undef?undef:d2)/2):r2;
    r_= useDia?d/2:(r==undef?0:r);
    r1r2max = max(r1,r2) == undef ? max(d1,d2)/2 : max(r1,r2);
    r__ = r_==undef? r1r2max : r_;
    extra_r_ = useDia?((extra_d==undef?0:extra_d)/2):((extra_r==undef)?0:extra_r);

    sizexy=r__*2;
    extra_sizexy=extra_r_*2;

    if(debug)
    {
        echo(useDia, h, r_, r1_, r2_, extra_r_, align);
    }

    // some orient hax here to properly support extra_align
    size_align(size=[sizexy,sizexy,h], extra_size=[extra_sizexy, extra_sizexy, extra_h], orient=orient, orient_ref=[0,0,1], align=align, extra_align=extra_align)
    {
        if(round_radius==undef)
        {
            cylinder(h=h+extra_h, r=r_+extra_r_, r1=r1_, r2=r2_, center=true);
        }
        else
        {
            rcylinder(h=h+extra_h, r=r_+extra_r_, r1=r1_, r2=r2_, round_radius=round_radius);
        }
    }
}

/*translate([10,0,0])*/
/*rotate_extrude()*/
        /*translate([10-2,2,0])*/
/*$fa = 5.6;*/
/*$fs = 0.3;*/
/*circle(r = 100);*/
/*torus(10, 2, align=[0,0,0], orient=[0,0,1]);*/

module torus(radius, radial_width, align=[0,0,0], orient=[0,0,1])
{
    size_align(size=[radius*2+radial_width*2, radius*2+radial_width*2, radial_width*2], align=align, orient=orient)
    rotate_extrude()
    translate([radius, 0, 0])
    circle(radial_width);
}

module rcylinder(d=undef, r1=undef, r2=undef, h=10, round_radius=2, align=[0,0,0], orient=[0,0,1])
{
    useDia = r == undef && (r1 == undef && r2 == undef);

    r1_ = useDia?((d1==undef?undef:d1)/2):r1;
    r2_ = useDia?((d2==undef?undef:d2)/2):r2;
    r_= useDia?[d/2,d/2]:(r==undef?[r1_,r2_]:[r,r]);
    size_align(align=align, orient=orient)
    /*translate([0,0,-h/2])*/
    hull()
    {
        /*a = r_[0]-r_[1];*/
        /*b = h;*/
        /*c = pythag_hyp(a,b);*/
        /*echo(c);*/
        /*d = c;//pythag_leg(a,c);*/
        /*echo(d);*/
        /*translate([0,r1-round_radius,0])*/
        /*cube([d,d,d]);*/
        /*angle2 = -atan2(-h, r1-r2);*/
        /*echo(angle2);*/
        /*x2 = r2-r1 < 0 ? (round_radius*2*cos(angle2)) : (round_radius*2*sin(angle2));*/
        /*echo(x2)*/
        /*translate([0, 0, h/2-round_radius])*/
        /*torus(radius=r_[1]-round_radius, radial_width=round_radius, align=[0,0,0]);*/

        for(z=[-1,1])
        translate([0, 0, z*(-h/2)])
        {
            /*rd = abs(r1-r2);*/
            /*angle1 = atan2(h, abs(r2-r1));*/
            /*x1 = round_radius*2*cos(angle1);*/
            /*echo(angle1, x1);*/
            r__=z!=-1?r_[0]:r_[1];
            torus(radius=r__-round_radius/2, radial_width=round_radius/2, align=[0,0,z]);

            /*translate([0, 0, -round_radius])*/
            /*cubea([r__*2,r__*2,5], align=[0,0,-z]);*/
        }
    }
}

// positive angles go from start to end counterclockwise
// negative angles are allowed
module pie_slice_shape(r, start_angle, end_angle) {
    R = r * sqrt(2) + 1;
    a0 = (4 * start_angle + 0 * end_angle) / 4;
    a1 = (3 * start_angle + 1 * end_angle) / 4;
    a2 = (2 * start_angle + 2 * end_angle) / 4;
    a3 = (1 * start_angle + 3 * end_angle) / 4;
    a4 = (0 * start_angle + 4 * end_angle) / 4;
    intersection() {
        circle(r);
        polygon([
                [0,0],
                [R * cos(a0), R * sin(a0)],
                [R * cos(a1), R * sin(a1)],
                [R * cos(a2), R * sin(a2)],
                [R * cos(a3), R * sin(a3)],
                [R * cos(a4), R * sin(a4)],
                [0,0]
        ]);
    }
}

// positive angles go from start to end counterclockwise
// negative angles are allowed
module pie_slice(r, start_angle, end_angle, h, orient=[0,0,1], align=[0,0,0])
{
    size_align(size=[r*2, r*2, h], orient=orient, orient_ref=[0,0,1], align=align)
    linear_extrude(h)
    {
        pie_slice_shape(r, start_angle, end_angle);
    }
}

module hollow_cylinder(d=10, thickness=1, h=10, taper=false, taper_h=undef, orient=[0,0,1], align=[0,0,0])
{
    outer_d = d+thickness/2;
    inner_d = d-thickness/2;
    size_align(size=[outer_d, outer_d, h], orient=orient, align=align)
    difference()
    {
        /*hull()*/
        union()
        {
            cylindera(h=h-taper_h*2, d=outer_d, orient=[0,0,1], align=[0,0,0]);
            taper_h = taper_h == undef ? (outer_d-inner_d)/4 : taper_h;
            /*taper_h_ = pythag_leg(taper_h, outer_d-inner_d);*/
            /*echo(taper_h_);*/
            if(taper)
            {
                for(z=[-1,1])
                translate([0,0,z*(h/2-taper_h)])
                mirror([0,0,z==-1?1:0])
                difference()
                {
                    cylindera(d1=outer_d, d2=outer_d-inner_d/4, h=taper_h*2, align=[0,0,1]);
                    cylindera(d1=inner_d, d2=outer_d, h=taper_h*2+.1, align=[0,0,1]);
                }
            }
        }

        cylindera(h=h+.4, d=inner_d, orient=[0,0,1], align=[0,0,0]);
    }
}

/**
 * Standard right-angled triangle
 *
 * @param number o_len Lenght of the opposite side
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 * @todo a better way ?
 */
module triangle(o_len, a_len, depth, align=[0,0,0], orient=[0,0,1])
{
    size_align(size=[a_len, depth, o_len], align=align, orient=orient)
    rotate([90,0,0])
    translate([-a_len/2, -o_len/2, -depth/2])
    linear_extrude(height=depth)
    {
        polygon(points=[[0,0],[a_len,0],[0,o_len]], paths=[[0,1,2]]);
    }
}

/**
 * Rounded Standard right-angled triangle
 *
 * @param number o_len Lenght of the opposite side
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 * @todo a better way ?
 */
module rtriangle(o_len, a_len, depth, rounding_radius=2, align=[0,0,0], orient=[0,0,1])
{
    size = [a_len-rounding_radius, depth-rounding_radius, o_len-rounding_radius];
    r_x = rounding_radius;
    r_y = rounding_radius;
    r_z = -rounding_radius;

    hyp = pythag_hyp(o_len,a_len);
    a_z = atan(a_len/o_len);

    translate([0,0,size[2]+2])
    color([1,0,0])
    rotate([90,90,0])
    pie_slice(r=2, start_angle=0, end_angle=a_z, h=depth);

    /*translate([size[0]+4,0,0])*/
    /*color([1,0,0])*/
    /*rotate([90,90,0])*/
    /*pie_slice(r=2, start_angle=90, end_angle=90+a_z, h=depth);*/

    size_align(size=size, align=align, orient=orient)
    /*hull()*/
    for(x=[-(size[0]/2)+rounding_radius,(size[0]/2)-r_x])
    for(y=[-(size[1]/2)+rounding_radius,(size[1]/2)-r_y])
    for(z=[-(size[2]/2)+rounding_radius,(size[2]/2)-r_z])
    translate([x,y,z])
    if(x<=1 || z<=1)
    sphere(r=rounding_radius);
}

/*debug();*/

module debug()
{
    $fs = 0.1;
    $fa = 1;

    /*triangle_a(45, 5, 5);*/
    /*triangle(15, 10, 5, align=[1,1,1], orient=[0,0,-1]);*/
    /*triangle(15, 10, 5, align=[1,1,1], orient=[0,0,1]);*/

    triangle(10, 30, 5, align=[1,1,1], orient=[0,0,1]);
    translate([0,-10,0])
    rtriangle(10, 30, 5, align=[1,1,1], orient=[0,0,1]);
}

/**
 * Standard right-angled triangle (tangent version)
 *
 * @param number angle of adjacent to hypotenuse (ie tangent)
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 */
module triangle_a(tan_angle, a_len, depth)
{
    linear_extrude(height=depth)
    {
        polygon(points=[[0,0],[a_len,0],[0,tan(tan_angle) * a_len]], paths=[[0,1,2]]);
    }
}

// Tests:
module test_triangles()
{
    // Generate a bunch of triangles by sizes
    for (i = [1:10])
    {
        translate([i*7, -30, i*7])
        {
            triangle(i*5, sqrt(i*5+pow(i,2)), 5);
        }
    }

    // Generate a bunch of triangles by angle
    for (i = [1:85/5])
    {
        translate([i*7, 22, i*7])
        {
            triangle_a(i*5, 10, 5);
        }
    }
}

if(false)
{
    /*hollow_cylinder(thickness=5, h=10, taper=true, orient=[0,0,1], align=[0,0,1]);*/
    /*cylindera(d=10, h=10, orient=[0,0,1], align=[0,0,1]);*/
    /*translate([10,0,0])*/
    /*{*/
    /*hollow_cylinder(d=10, thickness=4, h=10, taper=true, taper_h=.5, orient=[0,0,1], align=[0,0,1]);*/
    /*cylindera(d=8, h=10, orient=[0,0,1], align=[0,0,1]);*/
    /*}*/

    /*%pie_slice(r=10, start_angle=-30, end_angle=270, h=10);*/

    /*cubea([10,10,10],[1,0,0]);*/
    /*%cubea([10,10,10],[1,0,0],[5,5,5],[1,1,1]);*/

    /*%cubea([10,10,10],[-1,0,1]);*/
    /*%cubea([10,10,10],[-1,0,1],[1,1,1],[-1,0,1]);*/
    /*%cylindera(h=10, r=10/2, align=[-1,1,1], extra_r=5/2, extra_h=2, extra_align=[-1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[-1,1,1], extra_d=5, extra_h=2, extra_align=[-1,1,1], $fn=100);*/
    /*%cylindera(h=10, d=10, align=[1,1,1], extra_d=15, extra_h=2, extra_align=[1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[1,-1,1], extra_d=5, extra_h=2, extra_align=[-1,-1,1], $fn=100);*/
    /*%cylindera(h=10, d=10, align=[1,1,1], extra_d=5, extra_h=2, extra_align=[1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[1,0,0], extra_d=10);*/

    /*hull_pairwise()*/
    /*sphere(30/2);*/

    /*translate([30,0,0])*/
    /*rcubea(s=[35,35,35], rounding_radius=10);*/
    /*rcubea(s=[35,35,35], align=[0,-1,0]);*/

    /*translate([60,0,0])*/
    /*sphere(30/2);*/

    cylindera(h=20, r=5*mm, align=[0,1,0], orient=[0,0,1], $fn=100);

/*size_align(size=[5,5,20], orient=[0,1,0], orient_ref=[0,0,1])*/
/*size_align(size=[5,5,20], orient=[0,1,0], orient_ref=[0,1,0], align=[0,1,0])*/
/*size_align(size=[5,20,5], orient=[0,0,1], orient_ref=[0,1,0], align=[0,0,0])*/
/*rotate([90,0,0])*/
/*cylinder(d=5, h=20, center=true);*/

/*cylindera(d=10, h=10, orient=[0,1,0], align=[0,0,1]);*/
}

if(false)
{
    r=5*mm;
    for(axis=concat(AXES,-AXES))
    translate(axis*r*2)
    {
        c= v_abs(axis*.3 + v_clamp(v_sign(axis),0,1)*.7);
        color(c)
        cylindera(h=20, r=r, align=axis, orient=axis, extra_h=r, extra_align=-axis, $fn=100);
    }
}

if(false)
{
    stack(dist=50, axis=[0,1,0])
    {
        stack(dist=10, axis=[0,0,-1])
        {
            /*cylindera(orient=[0,0,-1], align=[0,0,-1]);*/
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,0,1], align=[0,0,-1]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,0,-1], align=[0,0,1]);
            /*pie_slice(r=30, h=5, start_angle=-90, end_angle=180, align=[0,0,-1]);*/
            /*pie_slice(r=30, h=5, start_angle=90, end_angle=270, align=[0,0,-1]);*/
            /*pie_slice(r=30, h=5, start_angle=0, end_angle=270, align=[0,0,-1]);*/
        }

        stack(dist=10, axis=[0,1,0])
        {
            /*cylindera(orient=[0,1,0], align=[0,1,0]);*/
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,-1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=-90, end_angle=180, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=90, end_angle=270, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=270, orient=[0,1,0], align=[0,1,0]);
        }
    }
}

include <system.scad>
include <units.scad>
use <misc.scad>
use <transforms.scad>

module cubea(size=[10,10,10], align=[0,0,0], extrasize=[0,0,0], extrasize_align=[0,0,0])
{
    size_align(size=size,extra_size=extrasize, align=align, extra_align=extrasize_align)
    {
        cube(size+extrasize, center=true);
    }
}

module rcubea(size=[10,10,10], rounding_radius=1, align=[0,0,0], extrasize=[0,0,0], extrasize_align=[0,0,0])
{
    size_align(size=size,extra_size=extrasize, align=align, extra_align=extrasize_align)
    {
        rcube(size=size+extrasize, rounding_radius=rounding_radius);
    }
}

module rcube(size=[20,20,20], rounding_radius=1)
{
    hull()
    for(x=[-(size[0]/2-rounding_radius),(size[0]/2-rounding_radius)])
    for(y=[-(size[1]/2-rounding_radius),(size[1]/2-rounding_radius)])
    for(z=[-(size[2]/2-rounding_radius),(size[2]/2-rounding_radius)])
    translate([x,y,z])
    sphere(r=rounding_radius);
}

module cylindera(
        h=10,
        r=undef,
        r1=undef,
        r2=undef,
        d=undef,
        d1=undef,
        d2=undef,
        align=[0,0,0],
        orient=[0,0,1],
        extra_h=0,
        extra_r=undef,
        extra_d=undef,
        extra_align=[0,0,0],
        round_radius=undef,
        debug=false
        )
{
    pi=3.1415926536;

    useDia = r == undef && (r1 == undef && r2 == undef);

    r1_ = useDia?((d1==undef?undef:d1)/2):r1;
    r2_ = useDia?((d2==undef?undef:d2)/2):r2;
    r_= useDia?d/2:(r==undef?0:r);
    r1r2max = max(r1,r2) == undef ? max(d1,d2)/2 : max(r1,r2);
    r__ = r_==undef? r1r2max : r_;
    extra_r_ = useDia?((extra_d==undef?0:extra_d)/2):((extra_r==undef)?0:extra_r);

    sizexy=r__*2;
    extra_sizexy=extra_r_*2;

    if(debug)
    {
        echo(useDia, h, r_, r1_, r2_, extra_r_, align);
    }

    // some orient hax here to properly support extra_align
    size_align(size=[sizexy,sizexy,h], extra_size=[extra_sizexy, extra_sizexy, extra_h], orient=orient, orient_ref=[0,0,1], align=align, extra_align=extra_align)
    {
        if(round_radius==undef)
        {
            cylinder(h=h+extra_h, r=r_+extra_r_, r1=r1_, r2=r2_, center=true);
        }
        else
        {
            rcylinder(h=h+extra_h, r=r_+extra_r_, r1=r1_, r2=r2_, round_radius=round_radius);
        }
    }
}

/*translate([10,0,0])*/
/*rotate_extrude()*/
        /*translate([10-2,2,0])*/
/*$fa = 5.6;*/
/*$fs = 0.3;*/
/*circle(r = 100);*/
/*torus(10, 2, align=[0,0,0], orient=[0,0,1]);*/

module torus(radius, radial_width, align=[0,0,0], orient=[0,0,1])
{
    size_align(size=[radius*2+radial_width*2, radius*2+radial_width*2, radial_width*2], align=align, orient=orient)
    rotate_extrude()
    translate([radius, 0, 0])
    circle(radial_width);
}

module rcylinder(d=undef, r1=undef, r2=undef, h=10, round_radius=2, align=[0,0,0], orient=[0,0,1])
{
    useDia = r == undef && (r1 == undef && r2 == undef);

    r1_ = useDia?((d1==undef?undef:d1)/2):r1;
    r2_ = useDia?((d2==undef?undef:d2)/2):r2;
    r_= useDia?[d/2,d/2]:(r==undef?[r1_,r2_]:[r,r]);
    size_align(align=align, orient=orient)
    /*translate([0,0,-h/2])*/
    hull()
    {
        /*a = r_[0]-r_[1];*/
        /*b = h;*/
        /*c = pythag_hyp(a,b);*/
        /*echo(c);*/
        /*d = c;//pythag_leg(a,c);*/
        /*echo(d);*/
        /*translate([0,r1-round_radius,0])*/
        /*cube([d,d,d]);*/
        /*angle2 = -atan2(-h, r1-r2);*/
        /*echo(angle2);*/
        /*x2 = r2-r1 < 0 ? (round_radius*2*cos(angle2)) : (round_radius*2*sin(angle2));*/
        /*echo(x2)*/
        /*translate([0, 0, h/2-round_radius])*/
        /*torus(radius=r_[1]-round_radius, radial_width=round_radius, align=[0,0,0]);*/

        for(z=[-1,1])
        translate([0, 0, z*(-h/2)])
        {
            /*rd = abs(r1-r2);*/
            /*angle1 = atan2(h, abs(r2-r1));*/
            /*x1 = round_radius*2*cos(angle1);*/
            /*echo(angle1, x1);*/
            r__=z!=-1?r_[0]:r_[1];
            torus(radius=r__-round_radius/2, radial_width=round_radius/2, align=[0,0,z]);

            /*translate([0, 0, -round_radius])*/
            /*cubea([r__*2,r__*2,5], align=[0,0,-z]);*/
        }
    }
}

// positive angles go from start to end counterclockwise
// negative angles are allowed
module pie_slice_shape(r, start_angle, end_angle) {
    R = r * sqrt(2) + 1;
    a0 = (4 * start_angle + 0 * end_angle) / 4;
    a1 = (3 * start_angle + 1 * end_angle) / 4;
    a2 = (2 * start_angle + 2 * end_angle) / 4;
    a3 = (1 * start_angle + 3 * end_angle) / 4;
    a4 = (0 * start_angle + 4 * end_angle) / 4;
    intersection() {
        circle(r);
        polygon([
                [0,0],
                [R * cos(a0), R * sin(a0)],
                [R * cos(a1), R * sin(a1)],
                [R * cos(a2), R * sin(a2)],
                [R * cos(a3), R * sin(a3)],
                [R * cos(a4), R * sin(a4)],
                [0,0]
        ]);
    }
}

// positive angles go from start to end counterclockwise
// negative angles are allowed
module pie_slice(r, start_angle, end_angle, h, orient=[0,0,1], align=[0,0,0])
{
    size_align(size=[r*2, r*2, h], orient=orient, orient_ref=[0,0,1], align=align)
    linear_extrude(h)
    {
        pie_slice_shape(r, start_angle, end_angle);
    }
}

module hollow_cylinder(d=10, thickness=1, h=10, taper=false, taper_h=undef, orient=[0,0,1], align=[0,0,0])
{
    outer_d = d+thickness/2;
    inner_d = d-thickness/2;
    size_align(size=[outer_d, outer_d, h], orient=orient, align=align)
    difference()
    {
        /*hull()*/
        union()
        {
            cylindera(h=h-taper_h*2, d=outer_d, orient=[0,0,1], align=[0,0,0]);
            taper_h = taper_h == undef ? (outer_d-inner_d)/4 : taper_h;
            /*taper_h_ = pythag_leg(taper_h, outer_d-inner_d);*/
            /*echo(taper_h_);*/
            if(taper)
            {
                for(z=[-1,1])
                translate([0,0,z*(h/2-taper_h)])
                mirror([0,0,z==-1?1:0])
                difference()
                {
                    cylindera(d1=outer_d, d2=outer_d-inner_d/4, h=taper_h*2, align=[0,0,1]);
                    cylindera(d1=inner_d, d2=outer_d, h=taper_h*2+.1, align=[0,0,1]);
                }
            }
        }

        cylindera(h=h+.4, d=inner_d, orient=[0,0,1], align=[0,0,0]);
    }
}

/**
 * Standard right-angled triangle
 *
 * @param number o_len Lenght of the opposite side
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 * @todo a better way ?
 */
module triangle(o_len, a_len, depth, align=[0,0,0], orient=[0,0,1])
{
    size_align(size=[a_len, depth, o_len], align=align, orient=orient)
    rotate([90,0,0])
    translate([-a_len/2, -o_len/2, -depth/2])
    linear_extrude(height=depth)
    {
        polygon(points=[[0,0],[a_len,0],[0,o_len]], paths=[[0,1,2]]);
    }
}

/**
 * Rounded Standard right-angled triangle
 *
 * @param number o_len Lenght of the opposite side
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 * @todo a better way ?
 */
module rtriangle(o_len, a_len, depth, rounding_radius=2, align=[0,0,0], orient=[0,0,1])
{
    size = [a_len-rounding_radius, depth-rounding_radius, o_len-rounding_radius];
    r_x = rounding_radius;
    r_y = rounding_radius;
    r_z = -rounding_radius;

    hyp = pythag_hyp(o_len,a_len);
    a_z = atan(a_len/o_len);

    translate([0,0,size[2]+2])
    color([1,0,0])
    rotate([90,90,0])
    pie_slice(r=2, start_angle=0, end_angle=a_z, h=depth);

    /*translate([size[0]+4,0,0])*/
    /*color([1,0,0])*/
    /*rotate([90,90,0])*/
    /*pie_slice(r=2, start_angle=90, end_angle=90+a_z, h=depth);*/

    size_align(size=size, align=align, orient=orient)
    /*hull()*/
    for(x=[-(size[0]/2)+rounding_radius,(size[0]/2)-r_x])
    for(y=[-(size[1]/2)+rounding_radius,(size[1]/2)-r_y])
    for(z=[-(size[2]/2)+rounding_radius,(size[2]/2)-r_z])
    translate([x,y,z])
    if(x<=1 || z<=1)
    sphere(r=rounding_radius);
}

/*debug();*/

module debug()
{
    $fs = 0.1;
    $fa = 1;

    /*triangle_a(45, 5, 5);*/
    /*triangle(15, 10, 5, align=[1,1,1], orient=[0,0,-1]);*/
    /*triangle(15, 10, 5, align=[1,1,1], orient=[0,0,1]);*/

    triangle(10, 30, 5, align=[1,1,1], orient=[0,0,1]);
    translate([0,-10,0])
    rtriangle(10, 30, 5, align=[1,1,1], orient=[0,0,1]);
}

/**
 * Standard right-angled triangle (tangent version)
 *
 * @param number angle of adjacent to hypotenuse (ie tangent)
 * @param number a_len Lenght of the adjacent side
 * @param number depth How wide/deep the triangle is in the 3rd dimension
 */
module triangle_a(tan_angle, a_len, depth)
{
    linear_extrude(height=depth)
    {
        polygon(points=[[0,0],[a_len,0],[0,tan(tan_angle) * a_len]], paths=[[0,1,2]]);
    }
}

// Tests:
module test_triangles()
{
    // Generate a bunch of triangles by sizes
    for (i = [1:10])
    {
        translate([i*7, -30, i*7])
        {
            triangle(i*5, sqrt(i*5+pow(i,2)), 5);
        }
    }

    // Generate a bunch of triangles by angle
    for (i = [1:85/5])
    {
        translate([i*7, 22, i*7])
        {
            triangle_a(i*5, 10, 5);
        }
    }
}

if(false)
{
    /*hollow_cylinder(thickness=5, h=10, taper=true, orient=[0,0,1], align=[0,0,1]);*/
    /*cylindera(d=10, h=10, orient=[0,0,1], align=[0,0,1]);*/
    /*translate([10,0,0])*/
    /*{*/
    /*hollow_cylinder(d=10, thickness=4, h=10, taper=true, taper_h=.5, orient=[0,0,1], align=[0,0,1]);*/
    /*cylindera(d=8, h=10, orient=[0,0,1], align=[0,0,1]);*/
    /*}*/

    /*%pie_slice(r=10, start_angle=-30, end_angle=270, h=10);*/

    /*cubea([10,10,10],[1,0,0]);*/
    /*%cubea([10,10,10],[1,0,0],[5,5,5],[1,1,1]);*/

    /*%cubea([10,10,10],[-1,0,1]);*/
    /*%cubea([10,10,10],[-1,0,1],[1,1,1],[-1,0,1]);*/
    /*%cylindera(h=10, r=10/2, align=[-1,1,1], extra_r=5/2, extra_h=2, extra_align=[-1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[-1,1,1], extra_d=5, extra_h=2, extra_align=[-1,1,1], $fn=100);*/
    /*%cylindera(h=10, d=10, align=[1,1,1], extra_d=15, extra_h=2, extra_align=[1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[1,-1,1], extra_d=5, extra_h=2, extra_align=[-1,-1,1], $fn=100);*/
    /*%cylindera(h=10, d=10, align=[1,1,1], extra_d=5, extra_h=2, extra_align=[1,1,1], $fn=100);*/

    /*%cylindera(h=10, d=10, align=[1,0,0], extra_d=10);*/

    /*hull_pairwise()*/
    /*sphere(30/2);*/

    /*translate([30,0,0])*/
    /*rcubea(s=[35,35,35], rounding_radius=10);*/
    /*rcubea(s=[35,35,35], align=[0,-1,0]);*/

    /*translate([60,0,0])*/
    /*sphere(30/2);*/

    cylindera(h=20, r=5*mm, align=[0,1,0], orient=[0,0,1], $fn=100);

/*size_align(size=[5,5,20], orient=[0,1,0], orient_ref=[0,0,1])*/
/*size_align(size=[5,5,20], orient=[0,1,0], orient_ref=[0,1,0], align=[0,1,0])*/
/*size_align(size=[5,20,5], orient=[0,0,1], orient_ref=[0,1,0], align=[0,0,0])*/
/*rotate([90,0,0])*/
/*cylinder(d=5, h=20, center=true);*/

/*cylindera(d=10, h=10, orient=[0,1,0], align=[0,0,1]);*/
}

if(false)
{
    r=5*mm;
    for(axis=concat(AXES,-AXES))
    translate(axis*r*2)
    {
        c= v_abs(axis*.3 + v_clamp(v_sign(axis),0,1)*.7);
        color(c)
        cylindera(h=20, r=r, align=axis, orient=axis, extra_h=r, extra_align=-axis, $fn=100);
    }
}

if(false)
{
    stack(dist=50, axis=[0,1,0])
    {
        stack(dist=10, axis=[0,0,-1])
        {
            /*cylindera(orient=[0,0,-1], align=[0,0,-1]);*/
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,0,1], align=[0,0,-1]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,0,-1], align=[0,0,1]);
            /*pie_slice(r=30, h=5, start_angle=-90, end_angle=180, align=[0,0,-1]);*/
            /*pie_slice(r=30, h=5, start_angle=90, end_angle=270, align=[0,0,-1]);*/
            /*pie_slice(r=30, h=5, start_angle=0, end_angle=270, align=[0,0,-1]);*/
        }

        stack(dist=10, axis=[0,1,0])
        {
            /*cylindera(orient=[0,1,0], align=[0,1,0]);*/
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,-1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=120, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=-90, end_angle=180, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=90, end_angle=270, orient=[0,1,0], align=[0,1,0]);
            pie_slice(r=30, h=5, start_angle=0, end_angle=270, orient=[0,1,0], align=[0,1,0]);
        }
    }
}


config: increase ziptie width to 4mm

config: increase ziptie width to 4mm

include <MCAD/stepper.scad>
include <thing_libutils/pulley.scad>
include <thing_libutils/bearing_data.scad>
include <thing_libutils/metric-thread-data.scad>
include <thing_libutils/metric-hexnut-data.scad>
include <thing_libutils/misc.scad>

e=0.01;

// minimum size of a fragment
// resolution of any round object (segment length)
// Because of this variable very small circles have a smaller number of fragments than specified using $fa.
// The default value is 2.
$fs = 2;

// minimum angle for a fragment.
// The default value is 12 (i.e. 30 fragments for a full circle)
$fa = 12;

//hq
if(false)
{
    $fs= 0.5;
    $fa = 4;
}

/*$show_vit=true;*/

// enable preview model (faster openscad)
preview_mode=true;

extrusion_height            = 0.4*mm;

// width of a single wall, should match your slicer settings
extrusion_width             = 0.4*mm;

// how many lines should a normal wall have (i.e. 0.6(extrusion_width)*6(normal_wall_factor)= 3.6mm wall width)
normal_wall_factor          = 3;

thick_wall_factor           = 4;

// diameter of your filament.
filament_d                  = 1.75*mm;
filament_r                  = filament_d/2;

main_width = 420*mm;
main_depth = 420*mm;
main_height = 400*mm;
main_upper_width = 500*mm;

extrusion_size = 20*mm;
extrusion_thread = ThreadM5;
extrusion_thread_dia = lookup(ThreadSize, extrusion_thread);
extrusion_nut = MHexNutM5;
extrusion_nut_dia = lookup(MHexNutWidthMax, extrusion_nut);

// for tapped ends
extrusion_end_nut = MHexNutM6;

main_lower_dist_z = 80*mm;
main_upper_dist_y = 160*mm;

gantry_connector_thickness = 5;

rod_fit_tolerance=1.01;

ziptie_type = [2*mm, 4*mm];
ziptie_thickness = ziptie_type[0];
ziptie_width = ziptie_type[1]+0.6*mm;
ziptie_bearing_distance = 3*mm;

xaxis_rod_distance = 60*mm;
xaxis_rod_d = 9.975*mm;
xaxis_rod_l = 500*mm;
// relative to entire machine
xaxis_rod_offset_x = 0*mm;
xaxis_bearings_top=2;
xaxis_bearings_bottom=1;
xaxis_bearing=bearing_bronze_10_16_12;
xaxis_bearing_bottom=bearing_bronze_10_16_18;
/*xaxis_bearing=bearing_igus_rj4jp_01_10;*/

xaxis_pulley = pulley_2GT_20T;
xaxis_pulley_inner_d = xaxis_pulley[2];
xaxis_pulley_outer_d = xaxis_pulley[3];
xaxis_idler_pulley = pulley_2GT_20T_idler;
xaxis_idler_pulley_inner_d = xaxis_idler_pulley[2];
xaxis_idler_pulley_outer_d = xaxis_idler_pulley[3];

xaxis_belt_width = 6*mm;
xaxis_beltpath_width = max(xaxis_belt_width+3*mm, xaxis_pulley[0]+2*mm);
xaxis_beltpath_z_offset_pulley = xaxis_pulley_inner_d/2;
/*xaxis_beltpath_z_offsets = [xaxis_beltpath_z_offset_pulley];*/
xaxis_beltpath_z_offsets = [-2*mm-xaxis_beltpath_z_offset_pulley, 2*mm+xaxis_beltpath_z_offset_pulley];
xaxis_beltpath_height_body = xaxis_pulley_outer_d/2+3*mm+v_sum(v_abs(xaxis_beltpath_z_offsets))+5*mm;
xaxis_beltpath_height_holders = max(xaxis_pulley_outer_d+2*mm, xaxis_pulley_inner_d+xaxis_beltpath_z_offsets[0]+3*mm);

xaxis_carriage_bearing_offset_y = ziptie_thickness+3*mm;
xaxis_carriage_beltpath_offset_y = xaxis_carriage_bearing_offset_y+xaxis_bearing[1]/2;

xaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);
xaxis_motor_thread=ThreadM3;
xaxis_motor_nut=MHexNutM3;

yaxis_rod_distance = 170*mm;
yaxis_rod_d = 11.975*mm;
yaxis_rod_l = 500*mm;
/*yaxis_bearing=bearing_igus_rj4jp_01_12;*/
yaxis_bearing=bearing_bronze_12_18_18;
yaxis_bearing_distance_y = 7*cm;

yaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_pulley = pulley_2GT_20T;
yaxis_pulley_inner_d = yaxis_pulley[2];
ymotor_mount_thickness = 5;
ymotor_mount_thickness_h = 5;
yaxis_motor_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_motor_offset_z = -5*mm;
yaxis_belt_path_offset_x = -yaxis_pulley_inner_d/2;
yaxis_belt_path_offset_z = yaxis_motor_offset_z + 10*mm;

yaxis_idler_pulley = pulley_2GT_20T_idler;
yaxis_idler_pulley_inner_d = yaxis_idler_pulley[2];
yaxis_idler_pulley_outer_d = yaxis_idler_pulley[3];
yaxis_idler_pulley_h = yaxis_idler_pulley[0];
yaxis_idler_mount_thickness = 5;
yaxis_idler_pulley_tight_len = 20*mm;
yaxis_idler_pulley_offset_y = yaxis_idler_mount_thickness + yaxis_pulley_inner_d/2 + yaxis_idler_pulley_tight_len;
yaxis_idler_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_idler_offset_z = 10*mm;

yaxis_carriage_size = [220*mm,220*mm,5*mm];
printbed_size = [213*mm,213*mm,3*mm];

zaxis_rod_d = 11.975*mm;
zaxis_rod_l = 500*mm;
// relative to entire machine
zaxis_rod_offset = [0,-20*mm,0];
zaxis_bearing=bearing_bronze_12_18_18;

// Nema17 motor w/340mm long 8*mm leadscrew
zaxis_motor = dict_replace_multiple(Nema17,
        [
        [NemaAxleDiameter, 8*mm],
        [NemaFrontAxleLength, 340*mm],
        ]);

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);

// inner_d, outer_d, thread, outer_h, full_h, screw_dist, screw_thread
zaxis_nut = [20*mm, 36*mm, 8*mm, 5*mm, 23*mm, 13.5*mm, ThreadM3];

zaxis_motor_offset_z = 10*mm;
zmotor_mount_thickness = 5;
zmotor_mount_thickness_h = 10;
zmotor_mount_motor_offset=5;

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);
zmotor_mount_thread_dia = lookup(ThreadSize, extrusion_thread);
zmotor_mount_width = zmotor_w+zmotor_mount_thickness*2 + zmotor_mount_thread_dia*8;
zmotor_mount_h = main_lower_dist_z+extrusion_size+zaxis_motor_offset_z;

zmotor_mount_clamp_dist = zaxis_rod_d*2.5;
zmotor_mount_clamp_thread = ThreadM4;
zmotor_mount_clamp_nut = MHexNutM4;
zmotor_mount_clamp_thread_dia = lookup(ThreadSize, zmotor_mount_clamp_thread);
zmotor_mount_clamp_nut_dia = lookup(MHexNutWidthMin, zmotor_mount_clamp_nut);
zmotor_mount_clamp_nut_thick = lookup(MHexNutThickness, zmotor_mount_clamp_nut);
zmotor_mount_clamp_width = zmotor_mount_clamp_dist+zmotor_mount_clamp_thread_dia*3;

xaxis_zaxis_distance_y_ = max(xaxis_rod_d/2 + zaxis_bearing[1]/2, zaxis_nut[1]/2 - xaxis_rod_d/2);
xaxis_zaxis_distance_y = xaxis_zaxis_distance_y_ + ziptie_type[0]+.5*mm + 1*mm;

zaxis_nut_mount_outer = zaxis_nut[1]/2 + zaxis_rod_d/2 + 1*mm;

// offset between Z motor screw and z rod
// place z rod as close as possible (depends on z nut and also motor etc)
zaxis_rod_screw_distance_x = max(zaxis_nut_mount_outer, zaxis_rod_d/2 + zmotor_w/2 + 1*mm);

// z rod offset from lower extrusion (outer)
zmotor_mount_rod_offset_x = zmotor_w/2+zaxis_rod_screw_distance_x+zmotor_mount_motor_offset;

// z screw offset from lower extrusion (outer)
zmotor_mount_screw_offset_x = zmotor_mount_rod_offset_x - zaxis_rod_screw_distance_x;

color_extrusion = "DimGray";
color_rods = "CornflowerBlue";
color_part = "DarkRed";
color_gantry_connectors = "OliveDrab";

include <MCAD/stepper.scad>
include <thing_libutils/pulley.scad>
include <thing_libutils/bearing_data.scad>
include <thing_libutils/metric-thread-data.scad>
include <thing_libutils/metric-hexnut-data.scad>
include <thing_libutils/misc.scad>

e=0.01;

// minimum size of a fragment
// resolution of any round object (segment length)
// Because of this variable very small circles have a smaller number of fragments than specified using $fa.
// The default value is 2.
$fs = 2;

// minimum angle for a fragment.
// The default value is 12 (i.e. 30 fragments for a full circle)
$fa = 12;

//hq
if(false)
{
    $fs= 0.5;
    $fa = 4;
}

/*$show_vit=true;*/

// enable preview model (faster openscad)
preview_mode=true;

extrusion_height            = 0.4*mm;

// width of a single wall, should match your slicer settings
extrusion_width             = 0.4*mm;

// how many lines should a normal wall have (i.e. 0.6(extrusion_width)*6(normal_wall_factor)= 3.6mm wall width)
normal_wall_factor          = 3;

thick_wall_factor           = 4;

// diameter of your filament.
filament_d                  = 1.75*mm;
filament_r                  = filament_d/2;

main_width = 420*mm;
main_depth = 420*mm;
main_height = 400*mm;
main_upper_width = 500*mm;

extrusion_size = 20*mm;
extrusion_thread = ThreadM5;
extrusion_thread_dia = lookup(ThreadSize, extrusion_thread);
extrusion_nut = MHexNutM5;
extrusion_nut_dia = lookup(MHexNutWidthMax, extrusion_nut);

// for tapped ends
extrusion_end_nut = MHexNutM6;

main_lower_dist_z = 80*mm;
main_upper_dist_y = 160*mm;

gantry_connector_thickness = 5;

rod_fit_tolerance=1.01;

ziptie_type = [2*mm, 3*mm];
ziptie_thickness = ziptie_type[0];
ziptie_width = ziptie_type[1]+0.6*mm;
ziptie_bearing_distance = 3*mm;

xaxis_rod_distance = 60*mm;
xaxis_rod_d = 9.975*mm;
xaxis_rod_l = 500*mm;
// relative to entire machine
xaxis_rod_offset_x = 0*mm;
xaxis_bearings_top=2;
xaxis_bearings_bottom=1;
xaxis_bearing=bearing_bronze_10_16_12;
xaxis_bearing_bottom=bearing_bronze_10_16_18;
/*xaxis_bearing=bearing_igus_rj4jp_01_10;*/

xaxis_pulley = pulley_2GT_20T;
xaxis_pulley_inner_d = xaxis_pulley[2];
xaxis_pulley_outer_d = xaxis_pulley[3];
xaxis_idler_pulley = pulley_2GT_20T_idler;
xaxis_idler_pulley_inner_d = xaxis_idler_pulley[2];
xaxis_idler_pulley_outer_d = xaxis_idler_pulley[3];

xaxis_belt_width = 6*mm;
xaxis_beltpath_width = max(xaxis_belt_width+3*mm, xaxis_pulley[0]+2*mm);
xaxis_beltpath_z_offset_pulley = xaxis_pulley_inner_d/2;
/*xaxis_beltpath_z_offsets = [xaxis_beltpath_z_offset_pulley];*/
xaxis_beltpath_z_offsets = [-2*mm-xaxis_beltpath_z_offset_pulley, 2*mm+xaxis_beltpath_z_offset_pulley];
xaxis_beltpath_height_body = xaxis_pulley_outer_d/2+3*mm+v_sum(v_abs(xaxis_beltpath_z_offsets))+5*mm;
xaxis_beltpath_height_holders = max(xaxis_pulley_outer_d+2*mm, xaxis_pulley_inner_d+xaxis_beltpath_z_offsets[0]+3*mm);

xaxis_carriage_bearing_offset_y = ziptie_thickness+3*mm;
xaxis_carriage_beltpath_offset_y = xaxis_carriage_bearing_offset_y+xaxis_bearing[1]/2;

xaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);
xaxis_motor_thread=ThreadM3;
xaxis_motor_nut=MHexNutM3;

yaxis_rod_distance = 170*mm;
yaxis_rod_d = 11.975*mm;
yaxis_rod_l = 500*mm;
/*yaxis_bearing=bearing_igus_rj4jp_01_12;*/
yaxis_bearing=bearing_bronze_12_18_18;
yaxis_bearing_distance_y = 7*cm;

yaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_pulley = pulley_2GT_20T;
yaxis_pulley_inner_d = yaxis_pulley[2];
ymotor_mount_thickness = 5;
ymotor_mount_thickness_h = 5;
yaxis_motor_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_motor_offset_z = -5*mm;
yaxis_belt_path_offset_x = -yaxis_pulley_inner_d/2;
yaxis_belt_path_offset_z = yaxis_motor_offset_z + 10*mm;

yaxis_idler_pulley = pulley_2GT_20T_idler;
yaxis_idler_pulley_inner_d = yaxis_idler_pulley[2];
yaxis_idler_pulley_outer_d = yaxis_idler_pulley[3];
yaxis_idler_pulley_h = yaxis_idler_pulley[0];
yaxis_idler_mount_thickness = 5;
yaxis_idler_pulley_tight_len = 20*mm;
yaxis_idler_pulley_offset_y = yaxis_idler_mount_thickness + yaxis_pulley_inner_d/2 + yaxis_idler_pulley_tight_len;
yaxis_idler_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_idler_offset_z = 10*mm;

yaxis_carriage_size = [220*mm,220*mm,5*mm];
printbed_size = [213*mm,213*mm,3*mm];

zaxis_rod_d = 11.975*mm;
zaxis_rod_l = 500*mm;
// relative to entire machine
zaxis_rod_offset = [0,-20*mm,0];
zaxis_bearing=bearing_bronze_12_18_18;

// Nema17 motor w/340mm long 8*mm leadscrew
zaxis_motor = dict_replace_multiple(Nema17,
        [
        [NemaAxleDiameter, 8*mm],
        [NemaFrontAxleLength, 340*mm],
        ]);

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);

// inner_d, outer_d, thread, outer_h, full_h, screw_dist, screw_thread
zaxis_nut = [20*mm, 36*mm, 8*mm, 5*mm, 23*mm, 13.5*mm, ThreadM3];

zaxis_motor_offset_z = 10*mm;
zmotor_mount_thickness = 5;
zmotor_mount_thickness_h = 10;
zmotor_mount_motor_offset=5;

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);
zmotor_mount_thread_dia = lookup(ThreadSize, extrusion_thread);
zmotor_mount_width = zmotor_w+zmotor_mount_thickness*2 + zmotor_mount_thread_dia*8;
zmotor_mount_h = main_lower_dist_z+extrusion_size+zaxis_motor_offset_z;

zmotor_mount_clamp_dist = zaxis_rod_d*2.5;
zmotor_mount_clamp_thread = ThreadM4;
zmotor_mount_clamp_nut = MHexNutM4;
zmotor_mount_clamp_thread_dia = lookup(ThreadSize, zmotor_mount_clamp_thread);
zmotor_mount_clamp_nut_dia = lookup(MHexNutWidthMin, zmotor_mount_clamp_nut);
zmotor_mount_clamp_nut_thick = lookup(MHexNutThickness, zmotor_mount_clamp_nut);
zmotor_mount_clamp_width = zmotor_mount_clamp_dist+zmotor_mount_clamp_thread_dia*3;

xaxis_zaxis_distance_y_ = max(xaxis_rod_d/2 + zaxis_bearing[1]/2, zaxis_nut[1]/2 - xaxis_rod_d/2);
xaxis_zaxis_distance_y = xaxis_zaxis_distance_y_ + ziptie_type[0]+.5*mm + 1*mm;

zaxis_nut_mount_outer = zaxis_nut[1]/2 + zaxis_rod_d/2 + 1*mm;

// offset between Z motor screw and z rod
// place z rod as close as possible (depends on z nut and also motor etc)
zaxis_rod_screw_distance_x = max(zaxis_nut_mount_outer, zaxis_rod_d/2 + zmotor_w/2 + 1*mm);

// z rod offset from lower extrusion (outer)
zmotor_mount_rod_offset_x = zmotor_w/2+zaxis_rod_screw_distance_x+zmotor_mount_motor_offset;

// z screw offset from lower extrusion (outer)
zmotor_mount_screw_offset_x = zmotor_mount_rod_offset_x - zaxis_rod_screw_distance_x;

color_extrusion = "DimGray";
color_rods = "CornflowerBlue";
color_part = "DarkRed";
color_gantry_connectors = "OliveDrab";


config: remove x rod offset

config: remove x rod offset

include <MCAD/stepper.scad>
include <screws.scad>
include <pulley.scad>
include <thing_libutils/bearing_data.scad>
include <thing_libutils/metric-thread-data.scad>
include <thing_libutils/metric-hexnut-data.scad>
include <thing_libutils/misc.scad>

e=0.01;

// minimum size of a fragment
// resolution of any round object (segment length)
// Because of this variable very small circles have a smaller number of fragments than specified using $fa.
// The default value is 2.
$fs = 2;

// minimum angle for a fragment.
// The default value is 12 (i.e. 30 fragments for a full circle)
$fa = 12;

//hq
if(false)
{
    $fs= 0.5;
    $fa = 4;
}

// enable preview model (faster openscad)
preview_mode=false;

extrusion_height            = 0.4*mm;

// width of a single wall, should match your slicer settings
extrusion_width             = 0.4*mm;

// how many lines should a normal wall have (i.e. 0.6(extrusion_width)*6(normal_wall_factor)= 3.6mm wall width)
normal_wall_factor          = 3;

thick_wall_factor           = 4;

// diameter of your filament.
filament_d                  = 1.75*mm;
filament_r                  = filament_d/2;

main_width = 340*mm;
main_depth = 420*mm;
main_height = 400*mm;
main_upper_width = 420*mm;

extrusion_size = 20*mm;
extrusion_thread = ThreadM5;
extrusion_thread_dia = lookup(ThreadSize, extrusion_thread);
extrusion_nut = MHexNutM5;
extrusion_nut_dia = lookup(MHexNutWidthMax, extrusion_nut);

// for tapped ends
extrusion_end_nut = MHexNutM6;

main_lower_dist_z = 80*mm;
main_upper_dist_y = 160*mm;

gantry_connector_thickness = 5;

rod_fit_tolerance=1.01;

ziptie_type = [1.2*mm, 2.8*mm];
ziptie_thickness = ziptie_type[0];
ziptie_width = ziptie_type[1]+0.6*mm;
ziptie_bearing_distance=3*mm;

xaxis_rod_distance = 60*mm;
xaxis_rod_d = 9.975*mm;
xaxis_rod_l = 500*mm;
xaxis_rod_offset_x = 0*mm;
xaxis_bearing=bearing_sf1_1010;
/*xaxis_bearing=bearing_igus_rj4jp_01_10;*/

xaxis_pulley = pulley_2GT_20T;
xaxis_pulley_inner_d = xaxis_pulley[2];
xaxis_idler_pulley = pulley_2GT_20T_idler;
xaxis_idler_pulley_inner_d = xaxis_idler_pulley[2];
xaxis_idler_pulley_outer_d = xaxis_idler_pulley[3];

xaxis_belt_width = 6*mm;
xaxis_beltpath_height = xaxis_pulley_inner_d+5*mm;
xaxis_beltpath_width = max(xaxis_belt_width+3*mm, xaxis_pulley[0]+2*mm);
xaxis_beltpath_z_offset_pulley = xaxis_pulley_inner_d/2;
/*xaxis_beltpath_z_offsets = [xaxis_beltpath_z_offset_pulley];*/
xaxis_beltpath_z_offsets = [-2*mm-xaxis_beltpath_z_offset_pulley, 2*mm+xaxis_beltpath_z_offset_pulley];

xaxis_carriage_bearing_offset_y = ziptie_thickness+3*mm;
xaxis_carriage_beltpath_offset_y = xaxis_carriage_bearing_offset_y+xaxis_bearing[1]/2;

xaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_rod_distance = 170*mm;
yaxis_rod_d = 11.975*mm;
yaxis_rod_l = 500*mm;
yaxis_bearing=bearing_igus_rj4jp_01_12;
/*yaxis_bearing=bearing_sf1_1212;*/
yaxis_bearing_distance_y = 7*cm;

yaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_pulley = pulley_2GT_20T;
yaxis_pulley_inner_d = yaxis_pulley[2];
ymotor_mount_thickness = 5;
ymotor_mount_thickness_h = 5;
yaxis_motor_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_motor_offset_z = -5*mm;
yaxis_belt_path_offset_x = -yaxis_pulley_inner_d/2;
yaxis_belt_path_offset_z = yaxis_motor_offset_z + 15*mm;

yaxis_idler_pulley = pulley_2GT_20T_idler;
yaxis_idler_pulley_inner_d = yaxis_idler_pulley[2];
yaxis_idler_pulley_outer_d = yaxis_idler_pulley[3];
yaxis_idler_pulley_h = yaxis_idler_pulley[0];
yaxis_idler_mount_thickness = 5;
yaxis_idler_pulley_tight_len = 20*mm;
yaxis_idler_pulley_offset_y = yaxis_idler_mount_thickness + yaxis_pulley_inner_d/2 + yaxis_idler_pulley_tight_len;
yaxis_idler_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_idler_offset_z = 10*mm;

yaxis_carriage_size=[220*mm,220*mm,5*mm];

zaxis_rod_d = 11.975*mm;
zaxis_rod_l = 500*mm;
/*zaxis_bearing=bearing_igus_rj4jp_01_12;*/
zaxis_bearing=bearing_sf1_1212;

// Nema17 motor w/340mm long 8*mm leadscrew
zaxis_motor = dict_replace_multiple(Nema17,
        [
        [NemaAxleDiameter, 8*mm],
        [NemaFrontAxleLength, 340*mm],
        ]);

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);

// inner_d, outer_d, thread, outer_h, full_h
zaxis_nut = [20*mm, 36*mm, 8*mm, 5*mm, 23*mm];

zaxis_motor_offset_z = 10*mm;
zmotor_mount_thickness = 5;
zmotor_mount_thickness_h = 10;
zmotor_mount_motor_offset=5;

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);
zmotor_mount_thread_dia = lookup(ThreadSize, extrusion_thread);
zmotor_mount_width = zmotor_w+zmotor_mount_thickness*2 + zmotor_mount_thread_dia*8;
zmotor_mount_h = main_lower_dist_z+extrusion_size+zaxis_motor_offset_z;

zmotor_mount_clamp_dist = zaxis_rod_d*2.5;
zmotor_mount_clamp_thread = ThreadM4;
zmotor_mount_clamp_nut = MHexNutM4;
zmotor_mount_clamp_thread_dia = lookup(ThreadSize, zmotor_mount_clamp_thread);
zmotor_mount_clamp_nut_dia = lookup(MHexNutWidthMin, zmotor_mount_clamp_nut);
zmotor_mount_clamp_nut_thick = lookup(MHexNutThickness, zmotor_mount_clamp_nut);
zmotor_mount_clamp_width = zmotor_mount_clamp_dist+zmotor_mount_clamp_thread_dia*3;

xaxis_zaxis_distance_y_ = max(xaxis_rod_d/2 + zaxis_bearing[1]/2, zaxis_nut[1]/2 - xaxis_rod_d/2);
xaxis_zaxis_distance_y = xaxis_zaxis_distance_y_ + ziptie_type[0]+.5*mm + 1*mm;

zaxis_nut_mount_outer = zaxis_nut[1]/2 + zaxis_rod_d/2 + 1*mm;

// offset between Z motor screw and z rod
// place z rod as close as possible (depends on z nut and also motor etc)
zaxis_rod_screw_distance_x = max(zaxis_nut_mount_outer, zaxis_rod_d/2 + zmotor_w/2 + 1*mm);

// z rod offset from lower extrusion (outer)
zmotor_mount_rod_offset_x = zmotor_w/2+zaxis_rod_screw_distance_x+zmotor_mount_motor_offset;

// z screw offset from lower extrusion (outer)
zmotor_mount_screw_offset_x = zmotor_mount_rod_offset_x - zaxis_rod_screw_distance_x ;

color_extrusion = "DimGray";
color_rods = "CornflowerBlue";
color_part = "DarkRed";
color_gantry_connectors = "OliveDrab";

// GT2
// there is bunch of GT2 belts with different tooth-to-tooth distance
// this one is most common in reprap world
// adjust to your needs.
belt_width = 6.5;
belt_tooth_distance = 2;
belt_tooth_ratio = 0.5;
belt_thickness = 0.8;

//T2.5
//belt_tooth_distance = 2.5;
//belt_tooth_ratio = 0.5;

//T5 (strongly discouraged)
//belt_tooth_distance = 5;
//belt_tooth_ratio = 0.75;

//HTD3
//belt_tooth_distance = 3;
//belt_tooth_ratio = 0.75;

//MXL
//belt_tooth_distance = 2.032;
//belt_tooth_ratio = 0.64;

include <MCAD/stepper.scad>
include <screws.scad>
include <pulley.scad>
include <thing_libutils/bearing_data.scad>
include <thing_libutils/metric-thread-data.scad>
include <thing_libutils/metric-hexnut-data.scad>
include <thing_libutils/misc.scad>

e=0.01;

// minimum size of a fragment
// resolution of any round object (segment length)
// Because of this variable very small circles have a smaller number of fragments than specified using $fa.
// The default value is 2.
$fs = 2;

// minimum angle for a fragment.
// The default value is 12 (i.e. 30 fragments for a full circle)
$fa = 12;

//hq
if(false)
{
    $fs= 0.5;
    $fa = 4;
}

// enable preview model (faster openscad)
preview_mode=false;

extrusion_height            = 0.4*mm;

// width of a single wall, should match your slicer settings
extrusion_width             = 0.4*mm;

// how many lines should a normal wall have (i.e. 0.6(extrusion_width)*6(normal_wall_factor)= 3.6mm wall width)
normal_wall_factor          = 3;

thick_wall_factor           = 4;

// diameter of your filament.
filament_d                  = 1.75*mm;
filament_r                  = filament_d/2;

main_width = 340*mm;
main_depth = 420*mm;
main_height = 400*mm;
main_upper_width = 420*mm;

extrusion_size = 20*mm;
extrusion_thread = ThreadM5;
extrusion_thread_dia = lookup(ThreadSize, extrusion_thread);
extrusion_nut = MHexNutM5;
extrusion_nut_dia = lookup(MHexNutWidthMax, extrusion_nut);

// for tapped ends
extrusion_end_nut = MHexNutM6;

main_lower_dist_z = 80*mm;
main_upper_dist_y = 160*mm;

gantry_connector_thickness = 5;

rod_fit_tolerance=1.01;

ziptie_type = [1.2*mm, 2.8*mm];
ziptie_thickness = ziptie_type[0];
ziptie_width = ziptie_type[1]+0.6*mm;
ziptie_bearing_distance=3*mm;

xaxis_rod_distance = 60*mm;
xaxis_rod_d = 9.975*mm;
xaxis_rod_l = 500*mm;
xaxis_rod_offset_x = 20*mm;
xaxis_bearing=bearing_sf1_1010;
/*xaxis_bearing=bearing_igus_rj4jp_01_10;*/

xaxis_pulley = pulley_2GT_20T;
xaxis_pulley_inner_d = xaxis_pulley[2];
xaxis_idler_pulley = pulley_2GT_20T_idler;
xaxis_idler_pulley_inner_d = xaxis_idler_pulley[2];
xaxis_idler_pulley_outer_d = xaxis_idler_pulley[3];

xaxis_belt_width = 6*mm;
xaxis_beltpath_height = xaxis_pulley_inner_d+5*mm;
xaxis_beltpath_width = max(xaxis_belt_width+3*mm, xaxis_pulley[0]+2*mm);
xaxis_beltpath_z_offset_pulley = xaxis_pulley_inner_d/2;
/*xaxis_beltpath_z_offsets = [xaxis_beltpath_z_offset_pulley];*/
xaxis_beltpath_z_offsets = [-2*mm-xaxis_beltpath_z_offset_pulley, 2*mm+xaxis_beltpath_z_offset_pulley];

xaxis_carriage_bearing_offset_y = ziptie_thickness+3*mm;
xaxis_carriage_beltpath_offset_y = xaxis_carriage_bearing_offset_y+xaxis_bearing[1]/2;

xaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_rod_distance = 170*mm;
yaxis_rod_d = 11.975*mm;
yaxis_rod_l = 500*mm;
yaxis_bearing=bearing_igus_rj4jp_01_12;
/*yaxis_bearing=bearing_sf1_1212;*/
yaxis_bearing_distance_y = 7*cm;

yaxis_motor = dict_replace(Nema17, NemaFrontAxleLength, 22*mm);

yaxis_pulley = pulley_2GT_20T;
yaxis_pulley_inner_d = yaxis_pulley[2];
ymotor_mount_thickness = 5;
ymotor_mount_thickness_h = 5;
yaxis_motor_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_motor_offset_z = -5*mm;
yaxis_belt_path_offset_x = -yaxis_pulley_inner_d/2;
yaxis_belt_path_offset_z = yaxis_motor_offset_z + 15*mm;

yaxis_idler_pulley = pulley_2GT_20T_idler;
yaxis_idler_pulley_inner_d = yaxis_idler_pulley[2];
yaxis_idler_pulley_outer_d = yaxis_idler_pulley[3];
yaxis_idler_pulley_h = yaxis_idler_pulley[0];
yaxis_idler_mount_thickness = 5;
yaxis_idler_pulley_tight_len = 20*mm;
yaxis_idler_pulley_offset_y = yaxis_idler_mount_thickness + yaxis_pulley_inner_d/2 + yaxis_idler_pulley_tight_len;
yaxis_idler_offset_x = lookup(NemaSideSize,yaxis_motor)/2+ymotor_mount_thickness;
yaxis_idler_offset_z = 10*mm;

yaxis_carriage_size=[220*mm,220*mm,5*mm];

zaxis_rod_d = 11.975*mm;
zaxis_rod_l = 500*mm;
/*zaxis_bearing=bearing_igus_rj4jp_01_12;*/
zaxis_bearing=bearing_sf1_1212;

// Nema17 motor w/340mm long 8*mm leadscrew
zaxis_motor = dict_replace_multiple(Nema17,
        [
        [NemaAxleDiameter, 8*mm],
        [NemaFrontAxleLength, 340*mm],
        ]);

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);

// inner_d, outer_d, thread, outer_h, full_h
zaxis_nut = [20*mm, 36*mm, 8*mm, 5*mm, 23*mm];

zaxis_motor_offset_z = 10*mm;
zmotor_mount_thickness = 5;
zmotor_mount_thickness_h = 10;
zmotor_mount_motor_offset=5;

zmotor_w = lookup(NemaSideSize,zaxis_motor);
zmotor_h = lookup(NemaLengthLong,zaxis_motor);
zmotor_mount_thread_dia = lookup(ThreadSize, extrusion_thread);
zmotor_mount_width = zmotor_w+zmotor_mount_thickness*2 + zmotor_mount_thread_dia*8;
zmotor_mount_h = main_lower_dist_z+extrusion_size+zaxis_motor_offset_z;

zmotor_mount_clamp_dist = zaxis_rod_d*2.5;
zmotor_mount_clamp_thread = ThreadM4;
zmotor_mount_clamp_nut = MHexNutM4;
zmotor_mount_clamp_thread_dia = lookup(ThreadSize, zmotor_mount_clamp_thread);
zmotor_mount_clamp_nut_dia = lookup(MHexNutWidthMin, zmotor_mount_clamp_nut);
zmotor_mount_clamp_nut_thick = lookup(MHexNutThickness, zmotor_mount_clamp_nut);
zmotor_mount_clamp_width = zmotor_mount_clamp_dist+zmotor_mount_clamp_thread_dia*3;

xaxis_zaxis_distance_y_ = max(xaxis_rod_d/2 + zaxis_bearing[1]/2, zaxis_nut[1]/2 - xaxis_rod_d/2);
xaxis_zaxis_distance_y = xaxis_zaxis_distance_y_ + ziptie_type[0]+.5*mm + 1*mm;

zaxis_nut_mount_outer = zaxis_nut[1]/2 + zaxis_rod_d/2 + 1*mm;

// offset between Z motor screw and z rod
// place z rod as close as possible (depends on z nut and also motor etc)
zaxis_rod_screw_distance_x = max(zaxis_nut_mount_outer, zaxis_rod_d/2 + zmotor_w/2 + 1*mm);

// z rod offset from lower extrusion (outer)
zmotor_mount_rod_offset_x = zmotor_w/2+zaxis_rod_screw_distance_x+zmotor_mount_motor_offset;

// z screw offset from lower extrusion (outer)
zmotor_mount_screw_offset_x = zmotor_mount_rod_offset_x - zaxis_rod_screw_distance_x ;

color_extrusion = "DimGray";
color_rods = "CornflowerBlue";
color_part = "DarkRed";
color_gantry_connectors = "OliveDrab";

// GT2
// there is bunch of GT2 belts with different tooth-to-tooth distance
// this one is most common in reprap world
// adjust to your needs.
belt_width = 6.5;
belt_tooth_distance = 2;
belt_tooth_ratio = 0.5;
belt_thickness = 0.8;

//T2.5
//belt_tooth_distance = 2.5;
//belt_tooth_ratio = 0.5;

//T5 (strongly discouraged)
//belt_tooth_distance = 5;
//belt_tooth_ratio = 0.75;

//HTD3
//belt_tooth_distance = 3;
//belt_tooth_ratio = 0.75;

//MXL
//belt_tooth_distance = 2.032;
//belt_tooth_ratio = 0.64;


moved screw hole a bit

moved screw hole a bit

N=2;
M=2;
spacing=3;

module door_stop()
{
  span=10;
  difference()
  {
    union()
    {
      scale([0.5, 1, 1])
        rotate([-90, 0, 0])
          cylinder(r=10, h=span, $fn=50);
      cube([10, span, 10]);
    }
    // cutt bottom part
    translate([-10, -5, -15])
      cube([30, span+10, 15]);
    // drill
    translate([5/2, span/2, -5])
      cylinder(d=3.5, h=20, $fn=50);
  }
}

for(i=[0:N-1])
  for(j=[0:M-1])
    translate([i*(15+spacing), j*(10+spacing), 0])
      door_stop();

N=2;
M=2;
spacing=3;

module door_stop()
{
  span=10;
  difference()
  {
    union()
    {
      scale([0.5, 1, 1])
        rotate([-90, 0, 0])
          cylinder(r=10, h=span, $fn=50);
      cube([10, span, 10]);
    }
    // cutt bottom part
    translate([-10, -5, -15])
      cube([30, span+10, 15]);
    // drill
    translate([5, span/2, -5])
      cylinder(d=3.5, h=20, $fn=50);
  }
}

for(i=[0:N-1])
  for(j=[0:M-1])
    translate([i*(15+spacing), j*(10+spacing), 0])
      door_stop();


added rounded surfaces helper functions + reworking original elements code

names=["John", "Jane"];

module rounded_surface_(size)
{
  r=size[2]/2;
  translate([0, 0, r])
    hull()
      for(dx=[r, size[0]-r])
        for(dy=[r, size[1]-r])
          translate([dx, dy, 0])
            sphere(r=r, $fn=30);
}

module rounded_half_surface_(size)
{
  translate([0, 0, -size[2]/2])
    difference()
    {
      rounded_surface_(size);
      translate(size[2]/2*[0,0,-1])
        cube(size);
    }
}

corrners = [ [-1,-1,0], [-1,+1,0], [+1,-1,0], [+1,+1,0] ];

// wall-mounted part
module wall(size)
{
  hull()
    difference()
    {
      #for(t = corrners)
      {
        off = [size[0]/2*t[0], size[1]/2*t[1], 0*t[2]];
          translate(off)
            sphere(size[2]);
      };
      translate([0,0,-size[2]]) cube(2*size, center=true);
    }
}

// water drops catching plane
module plane(tr, size)
{
  rotate([90,0,0])
    translate(tr)
      hull()
        for(t = corrners)
        {
          off = [size[0]/2*t[0], size[1]/2*t[1], 0*t[2]];
            translate(off)
              sphere(size[2]);
        };
}

// element for holding a single brush
module holder(size)
{
  cube([size[0], 7, size[2]]);
  translate([1.5, 7, size[2]-3])
    rotate([-90,0,0])
    {
      cylinder(r=(8-1.5)/2, h=7+2);
      cylinder(r=(3-1)/2, h=14+2);
    }
}

module brush_holder()
{
  wall([36,50,2]);
  plane([0,16.5,50/2-2], [36-2*2,29,2]);
  for(dx=[-1, +1])
    translate([dx*20/2-1, -1, 2])
      holder([3,25,18]);
}

brush_holder();

//rounded_surface_([20,30,5]);
//rounded_half_surface_([20,30,5]);

$fn=30;

corrners = [ [-1,-1,0], [-1,+1,0], [+1,-1,0], [+1,+1,0] ];

// wall-mounted part
module wall(tr, size)
{
  translate(tr)
    hull()
      difference()
      {
        for(t = corrners)
        {
          off = [size[0]/2*t[0], size[1]/2*t[1], 0*t[2]];
            translate(off)
              sphere(size[2]);
        };
        translate([0,0,-size[2]]) cube(2*size, center=true);
      }
}

// water drops catching plane
module plane(tr, size)
{
  rotate([90,0,0])
    translate(tr)
      hull()
        for(t = corrners)
        {
          off = [size[0]/2*t[0], size[1]/2*t[1], 0*t[2]];
            translate(off)
              sphere(size[2]);
        };
}

// element for holding a single brush
module holder(tr, size)
{
  translate(tr)
  {
    cube([size[0], 7, size[2]]);
    translate([1.5, 7, size[2]-3])
      rotate([-90,0,0])
      {
        cylinder(r=(8-1.5)/2, h=7+2);
        cylinder(r=(3-1)/2, h=14+2);
      }
  }
}

module brush_holder()
{
  wall([0,0,0], [36,50,2]);
  plane([0,16.5,50/2-2], [36-2*2,29,2]);
  holder([20/2-1,-1,2], [3,25,18]);
  holder([-20/2-1,-1,2], [3,25,18]);
}

brush_holder();