mirror of
https://github.com/BelfrySCAD/BOSL2.git
synced 2026-01-26 16:17:23 +00:00
Add two-halves print option with alignment pins
- Add print_mode parameter: single, top_half, bottom_half, both_halves - Create alignment pin system for precise half assembly - Support 2-3 configurable alignment pins with adjustable diameter - Add keychain_full() module for unified rendering - Implement intersection-based splitting at configurable height - Display assembly instructions in console for two-halves mode - Update documentation with three assembly methods - Add preview mode (both_halves) to check alignment - Simplify NFC tag insertion with glued assembly option
This commit is contained in:
Claude
parent
f275ff4f34
commit
7651e56d19
1 changed files with 257 additions and 62 deletions
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@ -9,10 +9,18 @@
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* - Set keychain_shape = "square" for rectangular design with rounded corners
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* - Set nfc_tag_hole = true/false to include/exclude NFC tag recess
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*
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* PRINT PAUSE FEATURE:
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* - When you open this file, the CONSOLE displays the exact pause height
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* - Set a pause in your slicer to insert the NFC tag mid-print
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* - The tag gets sealed inside as printing continues
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* THREE ASSEMBLY METHODS:
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* 1. Mid-Print Pause: Single piece with pause to insert NFC tag
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* - Console displays exact pause height
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* - Tag gets sealed during print
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*
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* 2. Two-Halves Assembly: Print top and bottom separately
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* - Set print_mode = "bottom_half" then "top_half"
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* - Built-in alignment pins for perfect fit
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* - Glue halves together with NFC tag inside
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* - Easiest method for consistent results
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*
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* 3. Post-Print: Glue tag in after printing
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*
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* To use your own photo/logo:
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* 1. Save your image file in the same directory as this .scad file
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@ -33,7 +41,10 @@ tag_color = "#FFFFFF"; // color
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// Keychain shape style
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keychain_shape = "oval"; // [oval, square]
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// Create a recessed hole for embedding NFC tag
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// Print mode: single piece or two halves for gluing
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print_mode = "single"; // [single, top_half, bottom_half, both_halves]
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// Create a recessed hole for embedding NFC tag (only for single piece mode)
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nfc_tag_hole = true;
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/* [Logo 1 Options - Front Side] */
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@ -144,6 +155,19 @@ square_corner_radius = 3;
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// Distance from bottom to center of hanging hole (only used if keychain_shape = "square")
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square_hole_distance = 43;
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/* [Two-Halves Print Options] */
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// Height at which to split the keychain (default is middle of total height)
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split_height = 0; // 0 = auto-calculate to middle
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// Add alignment pin holes for easier assembly
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add_alignment_pins = true;
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// Diameter of alignment pins
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alignment_pin_diameter = 2;
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// Number of alignment pins (2 or 3 recommended)
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alignment_pin_count = 3;
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// ============================================================
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// MODULES - Main Construction Code
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@ -299,80 +323,224 @@ module nfc_hole() {
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}
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}
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/*
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* Creates alignment pin holes for two-halves assembly
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*/
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module alignment_pins(pin_height, is_socket = false) {
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if (add_alignment_pins) {
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pin_radius = alignment_pin_diameter / 2;
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// Clearance for socket holes
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socket_radius = is_socket ? pin_radius + 0.2 : pin_radius;
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for (i = [0:alignment_pin_count-1]) {
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angle = 360 / alignment_pin_count * i;
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// Position pins around the perimeter
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rotate([0, 0, angle])
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translate([0, diameter1/2 - 5, 0])
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cylinder(h = pin_height, r = socket_radius, $fn=20);
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}
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}
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}
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/*
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* Main keychain assembly (full or split)
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*/
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module keychain_full() {
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difference() {
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// Main body
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union() {
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if (keychain_shape == "oval") {
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keychain_oval_with_ends();
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} else if (keychain_shape == "square") {
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keychain_square();
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}
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// Add alignment pins for bottom half
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if (print_mode == "bottom_half" && add_alignment_pins) {
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calculated_split = split_height > 0 ? split_height : (keychain_thickness + bevel_radius * 2) / 2;
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translate([0, 0, 0])
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alignment_pins(calculated_split, false);
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}
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}
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// Subtract NFC hole (only in single piece mode)
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if (print_mode == "single") {
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nfc_hole();
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}
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// Add alignment pin sockets for top half
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if (print_mode == "top_half" && add_alignment_pins) {
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calculated_split = split_height > 0 ? split_height : (keychain_thickness + bevel_radius * 2) / 2;
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translate([0, 0, 0])
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alignment_pins(calculated_split, true);
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}
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}
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}
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// ============================================================
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// RENDERING - Final Assembly
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// ============================================================
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// Calculate and display pause height for NFC tag insertion
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// Calculate dimensions
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pause_height = nfc_tag_height;
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total_height = keychain_thickness + bevel_radius * 2;
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calculated_split = split_height > 0 ? split_height : total_height / 2;
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// Display pause information in console
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// Display information in console
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echo(str("=============================================="));
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echo(str("PRINT PAUSE INFORMATION:"));
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echo(str("=============================================="));
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if (nfc_tag_hole) {
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echo(str("✓ NFC tag recess is ENABLED"));
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echo(str("Pause Height: ", pause_height, " mm"));
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echo(str("Total Height: ", total_height, " mm"));
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echo(str(""));
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echo(str("SLICER SETUP INSTRUCTIONS:"));
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echo(str("1. Slice this model normally"));
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echo(str("2. Add a pause at height: ", pause_height, " mm"));
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echo(str(" - PrusaSlicer: Right-click layer → Add pause print"));
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echo(str(" - Cura: Extensions → Post Processing → Modify G-Code → Pause at height"));
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echo(str(" - Bambu Studio: Right-click layer → Add pause"));
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echo(str("3. When printer pauses, place NFC tag in recess"));
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echo(str("4. Resume print to cover the tag"));
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if (print_mode == "single") {
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echo(str("PRINT MODE: Single Piece"));
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echo(str("=============================================="));
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if (nfc_tag_hole) {
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echo(str("✓ NFC tag recess is ENABLED"));
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echo(str("Pause Height: ", pause_height, " mm"));
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echo(str("Total Height: ", total_height, " mm"));
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echo(str(""));
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echo(str("SLICER SETUP INSTRUCTIONS:"));
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echo(str("1. Slice this model normally"));
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echo(str("2. Add a pause at height: ", pause_height, " mm"));
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echo(str(" - PrusaSlicer: Right-click layer → Add pause print"));
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echo(str(" - Cura: Extensions → Post Processing → Modify G-Code → Pause at height"));
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echo(str(" - Bambu Studio: Right-click layer → Add pause"));
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echo(str("3. When printer pauses, place NFC tag in recess"));
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echo(str("4. Resume print to cover the tag"));
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} else {
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echo(str("✗ NFC tag recess is DISABLED"));
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echo(str("Total Height: ", total_height, " mm"));
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}
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} else {
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echo(str("✗ NFC tag recess is DISABLED"));
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echo(str("PRINT MODE: Two-Halves Assembly"));
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echo(str("=============================================="));
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echo(str("Split Height: ", calculated_split, " mm"));
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echo(str("Total Height: ", total_height, " mm"));
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echo(str("Alignment Pins: ", add_alignment_pins ? "ENABLED" : "DISABLED"));
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if (add_alignment_pins) {
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echo(str("Pin Count: ", alignment_pin_count));
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echo(str("Pin Diameter: ", alignment_pin_diameter, " mm"));
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}
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echo(str(""));
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echo(str("ASSEMBLY INSTRUCTIONS:"));
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echo(str("1. Print both halves (set print_mode to 'bottom_half' then 'top_half')"));
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echo(str("2. Place NFC tag in the bottom half"));
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echo(str("3. Apply glue (CA glue or epoxy) to the mating surface"));
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echo(str("4. Align the halves using the pins"));
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echo(str("5. Press together and let cure"));
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}
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echo(str("=============================================="));
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// Main keychain body with NFC tag recess
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color(tag_color)
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difference() {
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// Render selected shape
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if (keychain_shape == "oval") {
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keychain_oval_with_ends();
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} else if (keychain_shape == "square") {
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keychain_square();
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}
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nfc_hole();
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// Main rendering based on print mode
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if (print_mode == "single") {
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// Single piece with optional NFC recess
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color(tag_color) {
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keychain_full();
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}
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// Calculate logo Y offset based on shape (square needs vertical centering)
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logo1YPosition = keychain_shape == "square"
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? logo1OffsetY + square_height/2 - 5 // Center on square body
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: logo1OffsetY;
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// Add logos
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logo1YPosition = keychain_shape == "square" ? logo1OffsetY + square_height/2 - 5 : logo1OffsetY;
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logo1ZOffset = logo1Type == "svg" ? keychain_thickness + bevel_radius - logo1Thickness/2 : keychain_thickness + bevel_radius - logo1Thickness + 0.01;
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// Front side logo (Logo 1)
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logo1ZOffset = logo1Type == "svg"
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? keychain_thickness + bevel_radius - logo1Thickness/2
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: keychain_thickness + bevel_radius - logo1Thickness + 0.01;
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color(logo1Color)
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translate([0, 0, logo1ZOffset])
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logo(logo1Type, logo1OffsetX, logo1YPosition, logo1Width, logo1Height, logo1Thickness, svgFile1, pngFile1, stlFile1);
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color(logo1Color)
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translate([0, 0, logo1ZOffset])
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logo(logo1Type, logo1OffsetX, logo1YPosition, logo1Width, logo1Height,
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logo1Thickness, svgFile1, pngFile1, stlFile1);
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if(logo2Enabled) {
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logo2YPosition = keychain_shape == "square" ? logo2OffsetY + square_height/2 - 5 : logo2OffsetY;
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logo2ZOffset = logo2Type == "svg" ? -bevel_radius + logo2Thickness/2 : -bevel_radius - 0.01 + logo2Thickness;
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color(logo2Color)
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translate([0, 0, logo2ZOffset])
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rotate([0, 180, 0])
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logo(logo2Type, logo2OffsetX, logo2YPosition, logo2Width, logo2Height, logo2Thickness, svgFile2, pngFile2, stlFile2);
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}
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} else if (print_mode == "bottom_half") {
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// Bottom half
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color(tag_color) {
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intersection() {
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keychain_full();
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translate([-100, -100, -0.1])
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cube([200, 200, calculated_split + 0.1]);
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}
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}
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// Back side logo (Logo 2) - Optional
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if(logo2Enabled) {
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// Calculate logo2 Y offset based on shape
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logo2YPosition = keychain_shape == "square"
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? logo2OffsetY + square_height/2 - 5
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: logo2OffsetY;
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// Add logo to bottom half (back side)
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if(logo2Enabled) {
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logo2YPosition = keychain_shape == "square" ? logo2OffsetY + square_height/2 - 5 : logo2OffsetY;
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logo2ZOffset = logo2Type == "svg" ? -bevel_radius + logo2Thickness/2 : -bevel_radius - 0.01 + logo2Thickness;
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intersection() {
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color(logo2Color)
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translate([0, 0, logo2ZOffset])
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rotate([0, 180, 0])
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logo(logo2Type, logo2OffsetX, logo2YPosition, logo2Width, logo2Height, logo2Thickness, svgFile2, pngFile2, stlFile2);
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translate([-100, -100, -0.1])
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cube([200, 200, calculated_split + 0.1]);
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}
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}
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} else if (print_mode == "top_half") {
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// Top half
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color(tag_color) {
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intersection() {
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keychain_full();
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translate([-100, -100, calculated_split])
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cube([200, 200, total_height]);
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}
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}
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logo2ZOffset = logo2Type == "svg"
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? -bevel_radius + logo2Thickness/2
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: -bevel_radius - 0.01 + logo2Thickness;
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// Add logo to top half (front side)
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logo1YPosition = keychain_shape == "square" ? logo1OffsetY + square_height/2 - 5 : logo1OffsetY;
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logo1ZOffset = logo1Type == "svg" ? keychain_thickness + bevel_radius - logo1Thickness/2 : keychain_thickness + bevel_radius - logo1Thickness + 0.01;
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color(logo2Color)
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translate([0, 0, logo2ZOffset])
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rotate([0, 180, 0])
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logo(logo2Type, logo2OffsetX, logo2YPosition, logo2Width, logo2Height,
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logo2Thickness, svgFile2, pngFile2, stlFile2);
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intersection() {
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color(logo1Color)
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translate([0, 0, logo1ZOffset])
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logo(logo1Type, logo1OffsetX, logo1YPosition, logo1Width, logo1Height, logo1Thickness, svgFile1, pngFile1, stlFile1);
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translate([-100, -100, calculated_split])
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cube([200, 200, total_height]);
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}
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} else if (print_mode == "both_halves") {
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// Show both halves side by side for preview
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spacing = keychain_shape == "oval" ? diameter1 + 5 : square_width + 5;
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// Bottom half
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translate([-spacing/2, 0, 0]) {
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color(tag_color) {
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intersection() {
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keychain_full();
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translate([-100, -100, -0.1])
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cube([200, 200, calculated_split + 0.1]);
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}
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}
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if(logo2Enabled) {
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logo2YPosition = keychain_shape == "square" ? logo2OffsetY + square_height/2 - 5 : logo2OffsetY;
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logo2ZOffset = logo2Type == "svg" ? -bevel_radius + logo2Thickness/2 : -bevel_radius - 0.01 + logo2Thickness;
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intersection() {
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color(logo2Color)
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translate([0, 0, logo2ZOffset])
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rotate([0, 180, 0])
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logo(logo2Type, logo2OffsetX, logo2YPosition, logo2Width, logo2Height, logo2Thickness, svgFile2, pngFile2, stlFile2);
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translate([-100, -100, -0.1])
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cube([200, 200, calculated_split + 0.1]);
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}
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}
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}
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// Top half
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translate([spacing/2, 0, 0]) {
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color(tag_color) {
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intersection() {
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keychain_full();
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translate([-100, -100, calculated_split])
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cube([200, 200, total_height]);
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}
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}
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logo1YPosition = keychain_shape == "square" ? logo1OffsetY + square_height/2 - 5 : logo1OffsetY;
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logo1ZOffset = logo1Type == "svg" ? keychain_thickness + bevel_radius - logo1Thickness/2 : keychain_thickness + bevel_radius - logo1Thickness + 0.01;
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intersection() {
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color(logo1Color)
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translate([0, 0, logo1ZOffset])
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logo(logo1Type, logo1OffsetX, logo1YPosition, logo1Width, logo1Height, logo1Thickness, svgFile1, pngFile1, stlFile1);
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translate([-100, -100, calculated_split])
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cube([200, 200, total_height]);
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}
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}
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}
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// ============================================================
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@ -384,20 +552,32 @@ if(logo2Enabled) {
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* SELECT YOUR VERSION:
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* Version 1 - Oval with NFC recess:
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* keychain_shape = "oval"
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* print_mode = "single"
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* nfc_tag_hole = true
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*
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* Version 2 - Oval without NFC recess:
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* keychain_shape = "oval"
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* print_mode = "single"
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* nfc_tag_hole = false
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*
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* Version 3 - Square with NFC recess:
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* keychain_shape = "square"
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* print_mode = "single"
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* nfc_tag_hole = true
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*
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* Version 4 - Square without NFC recess:
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* keychain_shape = "square"
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* print_mode = "single"
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* nfc_tag_hole = false
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*
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* Version 5 - Two-Halves Assembly (Oval):
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* keychain_shape = "oval"
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* print_mode = "bottom_half" or "top_half" or "both_halves"
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*
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* Version 6 - Two-Halves Assembly (Square):
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* keychain_shape = "square"
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* print_mode = "bottom_half" or "top_half" or "both_halves"
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*
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* 1. PREPARE YOUR IMAGE:
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* - For photos: Convert to SVG using online tools like:
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* * vectorizer.io
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@ -419,11 +599,12 @@ if(logo2Enabled) {
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* - Enable supports if needed for hanging hole
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* - Consider pause at layer for multi-color printing
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*
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* 5. NFC TAG INSERTION (IMPORTANT!):
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* 5. NFC TAG INSERTION (THREE METHODS):
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*
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* METHOD 1 - Mid-Print Pause (Best for single piece):
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* When you open this file in OpenSCAD, check the CONSOLE window.
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* It will display the exact pause height for your settings.
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*
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* TO INSERT NFC TAG DURING PRINT:
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* a) In your slicer, add a pause at the height shown in console
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* - PrusaSlicer: Right-click on the layer → "Add pause print (M601)"
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* - Cura: Extensions → Post Processing → Modify G-Code → "Pause at height"
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@ -431,7 +612,21 @@ if(logo2Enabled) {
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* b) When the print pauses, place your NFC tag in the recess
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* c) Resume printing - the remaining layers will seal the tag inside
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*
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* ALTERNATIVE METHOD:
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* METHOD 2 - Two-Halves Assembly (Easiest alignment):
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* a) Set print_mode = "bottom_half" and export/print
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* b) Set print_mode = "top_half" and export/print
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* c) Place NFC tag in the bottom half
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* d) Apply CA glue (super glue) or epoxy to the mating surface
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* e) Align using the built-in alignment pins
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* f) Press together firmly and let cure (60 seconds for CA glue)
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*
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* TIPS for Two-Halves:
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* - Set print_mode = "both_halves" to preview alignment
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* - Alignment pins ensure perfect registration
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* - Use thin CA glue for fastest assembly
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* - Apply glue sparingly to avoid squeeze-out
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*
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* METHOD 3 - Post-Print Glue:
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* - Print the keychain normally without pause
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* - Glue NFC tag into recess after printing
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* - Cover with thin layer of epoxy or clear nail polish if desired
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