joiners.scad

include <config.scad>
use <GDMUtils.scad>


module half_joiner_clear(h=20, w=10, a=30, clearance=0)
{
	dmnd_height = h*1.0;
	dmnd_width = dmnd_height*tan(a);
	guide_size = w/3;
	guide_width = 2*(dmnd_height/2-guide_size)*tan(a);

	difference() {
		// Diamonds.
		scale([w+clearance, dmnd_width/2, dmnd_height/2]) {
			xrot(45) cube(size=[1,sqrt(2),sqrt(2)], center=true);
		}
		// Blunt point of tab.
		grid_of(ya=[-(guide_width/2+2), (guide_width/2+2)]) {
			cube(size=[(w+clearance)*1.05, 4, h*0.99], center=true);
		}
	}
}
//half_joiner_clear();



module half_joiner(h=20, w=10, l=10, a=30, screwsize=undef, guides=true, slop=printer_slop)
{
	dmnd_height = h*1.0;
	dmnd_width = dmnd_height*tan(a);
	guide_size = w/3;
	guide_width = 2*(dmnd_height/2-guide_size)*tan(a);

	difference() {
		union() {
			// Make base.
			difference() {
				// Solid backing base.
				translate([0,-l/2,0])
					cube(size=[w, l, h], center=true);

				// Clear diamond for tab
				grid_of(xa=[-(w*2/3), (w*2/3)]) {
					half_joiner_clear(h=h+0.01, w=w, clearance=slop*2, a=a);
				}
			}

			difference() {
				// Make tab
				scale([w/3-slop*2, dmnd_width/2, dmnd_height/2]) xrot(45)
					cube(size=[1,sqrt(2),sqrt(2)], center=true);

				// Blunt point of tab.
				translate([0,guide_width/2+2,0])
					cube(size=[w*0.99,4,guide_size*2], center=true);
			}


			// Guide ridges.
			if (guides == true) {
				xspread(w/3-slop*2) {
					// Guide ridge.
					fwd(0.05/2) {
						scale([0.75, 1, 2]) yrot(45)
							cube(size=[guide_size/sqrt(2), guide_width+0.05, guide_size/sqrt(2)], center=true);
					}

					// Snap ridge.
					scale([0.25, 0.5, 1]) zrot(45)
						cube(size=[guide_size/sqrt(2), guide_size/sqrt(2), dmnd_width], center=true);
				}
			}
		}

		// Make screwholes, if needed.
		if (screwsize != undef) {
			yrot(90) cylinder(r=screwsize*1.1/2, h=w+1, center=true, $fn=12);
		}
	}
}
//half_joiner(screwsize=3);



module half_joiner2(h=20, w=10, l=10, a=30, screwsize=undef, guides=true)
{
	difference() {
		union () {
			translate([0,-l/2,0])
				cube(size=[w, l, h], center=true);
			half_joiner_clear(h=h, w=w, a=a);
		}

		// Subtract mated half_joiner.
		zrot(180) half_joiner(h=h+0.05, w=w+0.05, l=l+0.05, a=a, screwsize=undef, guides=guides, slop=0.0);

		// Make screwholes, if needed.
		if (screwsize != undef) {
			yrot(90) cylinder(r=screwsize*1.1/2, h=w+1, center=true, $fn=12);
		}
	}
}
//half_joiner2(screwsize=3);



module joiner(h=40, w=10, l=10, a=30, screwsize=undef, guides=true, slop=printer_slop)
{
	union() {
		translate([0,0,h/4])
			half_joiner(h=h/2, w=w, l=l, a=a, screwsize=screwsize, guides=guides, slop=slop);
		translate([0,0,-h/4])
			half_joiner2(h=h/2, w=w, l=l, a=a, screwsize=screwsize, guides=guides);
	}
}
//joiner(screwsize=3);



module joiner_clear(h=40, w=10, a=30, clearance=0)
{
	grid_of(za=[-h/4,h/4]) {
		half_joiner_clear(h=h/2.0, w=w, a=a, clearance=clearance);
	}
}
//joiner_clear();



module joiner_pair(spacing=100, h=40, w=10, l=10, a=30, screwsize=undef, guides=true)
{
	yrot_copies([0,180]) {
		translate([spacing/2, 0, 0]) {
			joiner(h=h, w=w, l=l, a=a, screwsize=screwsize, guides=guides);
		}
	}
}
//joiner_pair(spacing=100, h=40, w=10, l=10, a=30, screwsize=3, guides=true);



module joiner_pair_clear(spacing=100, h=40, w=10, a=30, clearance=0)
{
	yrot_copies([0,180]) {
		translate([spacing/2, 0, 0]) {
			joiner_clear(h=h, w=w, a=a, clearance=clearance);
		}
	}
}
//joiner_pair_clear(spacing=100, h=40, w=10, a=30);



module joiner_quad(xspacing=100, yspacing=50, h=40, w=10, l=10, a=30, screwsize=undef, guides=true)
{
	zrot_copies([0,180]) {
		translate([0, yspacing/2, 0]) {
			joiner_pair(spacing=xspacing, h=h, w=w, l=l, a=a, screwsize=screwsize, guides=guides);
		}
	}
}
//joiner_quad(xspacing=100, yspacing=50, h=40, w=10, l=10, a=30, screwsize=3, guides=true);



module joiner_quad_clear(xspacing=100, yspacing=50, h=40, w=10, a=30, clearance=0)
{
	zrot_copies([0,180]) {
		translate([0, yspacing/2, 0]) {
			joiner_pair_clear(spacing=xspacing, h=h, w=w, a=a, clearance=clearance);
		}
	}
}
//joiner_quad_clear(xspacing=100, yspacing=50, h=40, w=10, a=30);



// vim: noexpandtab tabstop=4 shiftwidth=4 softtabstop=4 nowrap