chocring-silicone.py

import math
from solidff import *
import solid

DEV = False

if DEV:
    num_len = 2
    num_width = 2
else:
    num_len = 4
    num_width = 9

channel_width = 0.5
hole_len = 3
hole_width = 1.2
hole_dist = 4.4
tolerance = 0.1
stem_len = 10
stem_width = 4.3
stem_nub_width = 3
stem_nub_depth = 1
thick = 0.75
wall_thick = 1
base_thick = 3
corner_r = 0.5
expand_r = 1.25
rail_gap = 0.5
total_thick = base_thick + thick
rail_offset = rail_gap + 1
bar_width = 1.5

base = s(stem_len, stem_width, True)
nub = s(stem_nub_width, stem_nub_depth).x(-stem_nub_width/2).y(stem_width / 2)
out_shape = (base + nub).o(delta=-(expand_r - corner_r)).o(r=expand_r + tolerance)
wall_height = thick + base_thick

hole = s(hole_width, hole_len).y(-hole_len / 2).x(hole_dist / 2).o(r=tolerance)
holes = (hole + hole.r(180))
mask = (mask_sketch := (out_shape - holes)).e(thick + 0.01)

mold_width = stem_width + stem_nub_depth + 2 * tolerance + wall_thick + 2 * 0.5
mold_len = stem_len + 2 * tolerance + wall_thick + 2 * 0.5
mold = s(mold_len, mold_width).e(total_thick).z(-base_thick)
stem_x_center = wall_thick / 2 + stem_len / 2 + 0.5 + tolerance
mold -= mask.r(180).t(stem_x_center, wall_thick + stem_width / 2 + 0.5 + tolerance + stem_nub_depth)
mold -= q(channel_width, wall_thick, thick).x(stem_x_center - channel_width / 2)
if not DEV:
    mold = mold.render()

base_len = wall_thick + num_len * mold_len
base_width = wall_thick + num_width * mold_width
col = sum(mold.y(mold_width * i) for i in range(num_width))
# col += q(mold_len, wall_thick, total_thick).z(-base_thick).y(-wall_thick)
# col -= (funnel := b(r=wall_thick).t(stem_x_center, -wall_thick)).z(thick / 2) + funnel.z(-base_thick - thick / 2)
cols = sum(col.x(mold_len * i) for i in range(num_len))
total_width = mold_width * num_width
total_len = mold_len * num_len

half_bar_gap = (base_thick - bar_width) / 2

side_frame = q(wall_thick, total_width, total_thick).z(-base_thick)
side_frame += q(wall_thick, total_width + wall_thick + bar_width, total_thick - rail_gap).t(wall_thick, -bar_width, -base_thick + rail_offset)
bot_frame = q(total_len + 2*wall_thick, wall_thick, total_thick).z(-base_thick).t(-wall_thick, total_width)
top_bar = q(total_len + 2*wall_thick, bar_width, bar_width).t(-wall_thick, -bar_width, -half_bar_gap - bar_width)
frames = side_frame.m(1, 0, 0) + side_frame.x(total_len) + bot_frame + top_bar

cover_thick = half_bar_gap + bar_width

whole = cols + frames
cover = q(total_len + 2*wall_thick, total_width + wall_thick, cover_thick).x(-wall_thick) + q(total_len + 2*wall_thick, bar_width, bar_width).t(-wall_thick, -bar_width, half_bar_gap)

def masks_sketch():
    col = sum(mask_sketch.y(mold_width * i) for i in range(num_width))
    cols = sum(col.x(mold_len * i) for i in range(num_len))
    return cols

def masks_sketch2(num_rows, num_cols):
    row = sum(mask_sketch.x(mold_len * i) for i in range(num_cols))
    flipped = mask_sketch.r(180).t(mold_len / 2, mold_width - 0.25)
    flipped_row = sum(flipped.x(mold_len * i) for i in range(num_cols - 1))
    group = row + flipped_row
    group_width = 2 * wall_thick + stem_width + mold_width
    return sum(group.y(group_width * i) for i in range(num_rows)).t(stem_x_center + wall_thick, wall_thick + stem_width / 2 + 0.5 + tolerance + stem_nub_depth)

cover.dump("cover.scad")
masks_sketch2(4, 10).dump("mask.scad")
whole.dump_this()

chocring-silicone.stl

cover.stl

mask.scad

mask.svg