STL cooling rack generator

config.yaml

width: 600               # Width of the cooling rack in mm
depth: 800               # Depth of the cooling rack in mm
height: 2200             # Total height of the rack in mm
grid_spacing: 50         # Spacing between grid bars in mm
rack_bar_thickness: 2    # Thickness of the rack bars in mm
frame_thickness: 25      # Thickness of the frame and legs in mm
leg_height: 100          # Height of the legs in mm
num_levels: 8            # Number of stacked levels
file_path: "Cooling_Rack_With_Vertical_Frame.stl"  # Output STL file path

main.py

import numpy as np
from stl import mesh
from mpl_toolkits.mplot3d import Axes3D, art3d
import matplotlib.pyplot as plt
import hydra
from omegaconf import DictConfig

def create_bar(start, end, thickness):
    print(f"Creating bar from {start} to {end} with thickness {thickness}")

    delta = np.array(end) - np.array(start)
    if delta[0] != 0:  # Bar extends along the x-axis
        vertices = np.array([
            [start[0], start[1] - thickness / 2, start[2] - thickness / 2],
            [end[0],   start[1] - thickness / 2, start[2] - thickness / 2],
            [end[0],   start[1] + thickness / 2, start[2] - thickness / 2],
            [start[0], start[1] + thickness / 2, start[2] - thickness / 2],

            [start[0], start[1] - thickness / 2, start[2] + thickness / 2],
            [end[0],   start[1] - thickness / 2, start[2] + thickness / 2],
            [end[0],   start[1] + thickness / 2, start[2] + thickness / 2],
            [start[0], start[1] + thickness / 2, start[2] + thickness / 2],
        ])
    elif delta[1] != 0:  # Bar extends along the y-axis
        vertices = np.array([
            [start[0] - thickness / 2, start[1], start[2] - thickness / 2],
            [end[0]   - thickness / 2, end[1],   start[2] - thickness / 2],
            [end[0]   + thickness / 2, end[1],   start[2] - thickness / 2],
            [start[0] + thickness / 2, start[1], start[2] - thickness / 2],

            [start[0] - thickness / 2, start[1], start[2] + thickness / 2],
            [end[0]   - thickness / 2, end[1],   start[2] + thickness / 2],
            [end[0]   + thickness / 2, end[1],   start[2] + thickness / 2],
            [start[0] + thickness / 2, start[1], start[2] + thickness / 2],
        ])
    elif delta[2] != 0:  # Bar extends along the z-axis
        vertices = np.array([
            [start[0] - thickness / 2, start[1] - thickness / 2, start[2]],
            [start[0] + thickness / 2, start[1] - thickness / 2, start[2]],
            [start[0] + thickness / 2, start[1] + thickness / 2, start[2]],
            [start[0] - thickness / 2, start[1] + thickness / 2, start[2]],

            [start[0] - thickness / 2, start[1] - thickness / 2, end[2]],
            [start[0] + thickness / 2, start[1] - thickness / 2, end[2]],
            [start[0] + thickness / 2, start[1] + thickness / 2, end[2]],
            [start[0] - thickness / 2, start[1] + thickness / 2, end[2]],
        ])
    else:
        raise ValueError("Start and end coordinates must define a bar along x, y, or z axis.")

    # Define faces using two triangles per rectangular face
    faces = np.array([
        [0, 1, 2], [0, 2, 3],   # Bottom face
        [4, 5, 6], [4, 6, 7],   # Top face
        [0, 1, 5], [0, 5, 4],   # Front face
        [1, 2, 6], [1, 6, 5],   # Right face
        [2, 3, 7], [2, 7, 6],   # Back face
        [3, 0, 4], [3, 4, 7],   # Left face
    ])

    bar_mesh = mesh.Mesh(np.zeros(faces.shape[0], dtype=mesh.Mesh.dtype))
    for i, f in enumerate(faces):
        for j in range(3):
            bar_mesh.vectors[i][j] = vertices[f[j]]

    return bar_mesh

    # Define faces using the vertices
    faces = np.array([
        [0, 1, 2], [0, 2, 3],  # Bottom face
        [4, 5, 6], [4, 6, 7],  # Top face
        [0, 1, 5], [0, 5, 4],  # Front face
        [1, 2, 6], [1, 6, 5],  # Right face
        [2, 3, 7], [2, 7, 6],  # Back face
        [3, 0, 4], [3, 4, 7],  # Left face
    ])

    # Fix diagonal face alignment for better rendering
    faces = np.concatenate([
        [[0, 1, 4], [1, 5, 4]],  # Adjust diagonals for Front
        [[1, 2, 5], [2, 6, 5]],  # Adjust diagonals for Right
        [[2, 3, 6], [3, 7, 6]],  # Adjust diagonals for Back
        [[3, 0, 7], [0, 4, 7]],  # Adjust diagonals for Left
    ])

    # Create mesh
    bar_mesh = mesh.Mesh(np.zeros(faces.shape[0], dtype=mesh.Mesh.dtype))
    for i, f in enumerate(faces):
        for j in range(3):
            bar_mesh.vectors[i][j] = vertices[f[j]]

    return bar_mesh

@hydra.main(config_path=".", config_name="config", version_base=None)
def main(cfg: DictConfig):
    print("Configuration Loaded:", cfg)

    width = cfg.width
    depth = cfg.depth
    height = cfg.height
    grid_spacing = cfg.grid_spacing
    rack_bar_thickness = cfg.rack_bar_thickness
    frame_thickness = cfg.frame_thickness
    leg_height = cfg.leg_height
    num_levels = cfg.num_levels

    print(f"Dimensions: width={width}, depth={depth}, height={height}")
    print(f"Grid spacing: {grid_spacing}, Rack bar thickness: {rack_bar_thickness}, Frame thickness: {frame_thickness}")
    print(f"Leg height: {leg_height}, Number of levels: {num_levels}")

    bars = []

    # Add horizontal grid levels
    level_height = (height - leg_height) / (num_levels - 1)
    print(f"Calculated level height: {level_height}")

    for level in range(num_levels):
        z = leg_height + level * level_height
        print(f"Adding horizontal grid at z={z}")

        for y in range(0, depth + grid_spacing, grid_spacing):
            start = [0, y, z]
            end = [width, y, z]
            bars.append(create_bar(start, end, rack_bar_thickness))

        for x in range(0, width + grid_spacing, grid_spacing):
            start = [x, 0, z]
            end = [x, depth, z]
            bars.append(create_bar(start, end, rack_bar_thickness))

    # Add vertical corner frames (four corners)
    corner_positions = [(0, 0), (0, depth), (width, 0), (width, depth)]
    for i, pos in enumerate(corner_positions):
        start = [pos[0], pos[1], 0]
        end = [pos[0], pos[1], height]
        print(f"Adding vertical corner frame {i} from {start} to {end}")
        bars.append(create_bar(start, end, frame_thickness))

    # Combine all bars into one mesh
    print(f"Total number of bars: {len(bars)}")
    combined_mesh = mesh.Mesh(np.concatenate([bar.data for bar in bars]))
    print(f"Combined mesh has {len(combined_mesh.vectors)} triangles.")

    file_path = cfg.file_path
    combined_mesh.save(file_path)
    print(f"Cooling rack STL file saved at: {file_path}")

    # Visualize the model
    fig = plt.figure(figsize=(10, 8))
    ax = fig.add_subplot(111, projection="3d")
    ax.add_collection3d(
        art3d.Poly3DCollection(combined_mesh.vectors, alpha=1.0, edgecolor="k")
    )
    ax.auto_scale_xyz([0, width], [0, depth], [0, height])
    plt.savefig("visualization_debug_highres.png", dpi=300)
    print("Visualization saved as visualization_debug_highres.png")
    plt.show()

if __name__ == "__main__":
    main()