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Exploratory scripts for laser cutter
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ill-tempered-seabass/battery-case-generator.py

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  1. #!/usr/bin/env python3

  2. 

  3. import math

  4. import sys

  5. import argparse

  6. import svgturtle

  7. 

  8. parser = argparse.ArgumentParser(description='Generate a hexagonal battery case')

  9. parser.add_argument('--dimension', default=5, type=int, help='Grid dimension')

  10. parser.add_argument('--height', type=float, help='Height of battery')

  11. parser.add_argument('--hole', default='AA', help='Hole diameter (mm or A, AA, AAA)')

  12. parser.add_argument('--kerf', default=.1, type=float, help='Kerf')

  13. parser.add_argument('--corner-length', default=4, help='Length of stretch corner in material thicknesses')

  14. parser.add_argument('--stretch', default=1.05, type=float, help='Reduction factor of stretch material')

  15. parser.add_argument('--horizontal-finger', default=5.0, type=float, help='Width of horizontal fingers')

  16. parser.add_argument('--vertical-finger', default=15.0, type=float, help='Width of vertical fingers')

  17. parser.add_argument('--padding', default=1.5, type=float, help='Padding around holes')

  18. parser.add_argument('--outside-padding', default=4.0, type=float, help='Extra padding between holes and wall')

  19. parser.add_argument('--extra-height', default=2.0, type=float, help='Extra vertical space')

  20. parser.add_argument('--thickness', default=3.0, type=float, help='Thickness of material')

  21. parser.add_argument('--lid', default=0.2, type=float, help='How much extra play to give the lid')

  22. parser.add_argument('--tooth', default=0.8, type=float, help='How much to round the edges of the teeth')

  23. parser.add_argument('--flex-width', default=.5, type=float, help='Spacing (in material thickness) between flex lines')

  24. parser.add_argument('--flex-cut', default=5.0, type=float, help='Length (in material thickness) of flex cuts')

  25. parser.add_argument('--flex-gap', default=1.0, type=float, help='Gap (in material thickness) between flex cuts')

  26. parser.add_argument('--plug-play', default=0.8, type=float, help='How much smaller to make the plug than the hole')

  27. parser.add_argument('--verbose', action='store_true', help='Print computed parameter values')

  28. args = parser.parse_args()

  29. assert (args.dimension % 2) == 1

  30. 

  31. BATTERY = {

  32.     'AAA': [10.5, 44.5],

  33.     'AA':  [14.5, 50.5],

  34.     'C':   [26.2, 50.0],

  35.     'D':   [34.2, 61.5],

  36. }

  37. 

  38. if args.hole in BATTERY:

  39.     dim = BATTERY[args.hole]

  40.     args.hole = dim[0]

  41.     if args.height == None:

  42.         args.height = dim[1]

  43. else:

  44.     args.hole = float(args.hole)

  45.     assert(args.height != None)

  46. 

  47. SUITABLE = False

  48. while not SUITABLE:

  49.     args.kerf2         = args.kerf/2

  50.     args.grid          = args.hole+args.padding

  51.     args.radius        = args.hole/2

  52.     args.corner        = args.corner_length*args.thickness

  53.     args.corner_s      = args.corner*args.stretch

  54.     args.corner_radius = 3*args.corner_s/math.pi

  55.     args.plug_radius   = args.corner_radius-args.thickness

  56.     args.corner_inset  = args.corner_s*math.sqrt(3)/math.pi

  57.     args.plug_inset    = args.plug_radius/math.sqrt(3)

  58.     args.interior_edge = args.grid*args.dimension*0.5+args.outside_padding

  59.     args.opening_edge  = args.interior_edge-args.thickness

  60.     args.plug_edge     = min(args.opening_edge, .5*math.sqrt(3)*args.interior_edge)-args.plug_play

  61.     args.disc_radius   = 0.45*(math.sqrt(3)-1)*args.plug_edge+args.plug_inset

  62.     args.exterior_edge = args.interior_edge+2.0*args.thickness

  63.     args.interior_leg  = (args.interior_edge-args.horizontal_finger-args.kerf)/2-args.corner_inset

  64.     finger_length      = args.interior_edge-2.0*args.corner_inset

  65.     args.n_hor_fingers = max(int(finger_length/args.horizontal_finger/2), 1)

  66.     args.exterior_leg  = (finger_length-(2*args.n_hor_fingers-1)*args.horizontal_finger+args.kerf)/2

  67.     args.wall_leg      = (args.interior_edge-args.corner-(2*args.n_hor_fingers-1)*args.horizontal_finger+args.kerf)/2

  68.     args.exterior_slot = (args.interior_edge-args.horizontal_finger+args.kerf)/2

  69.     args.n_ver_fingers = int((args.height+args.extra_height)/args.vertical_finger)

  70.     top_slot           = args.extra_height+args.thickness+0.45*args.height

  71.     args.slots         = [top_slot, top_slot+15.0]

  72.     if args.exterior_leg > 2:

  73.         SUITABLE=True

  74.     else:

  75.         args.outside_padding += .5

  76.         args.padding         += .2 # Try again with more padding

  77. 

  78. if args.verbose:

  79.     print(args, file=sys.stderr)

  80. 

  81. BOX    = 2.0*args.exterior_edge+5.0

  82. DIMX   = 3.0*BOX

  83. DIMY   = 2.0*BOX+args.height+args.extra_height+3.0*args.thickness+5.0

  84. PI3    = math.pi/3

  85. 

  86. HOLES  = ''

  87. SHAPES = ''

  88. MARKS  = ''

  89. 

  90. def draw_grid(cx, cy):

  91.     global HOLES

  92.     for row in range(-int(args.dimension/2), int((args.dimension+1)/2)):

  93.         cyr = cy+args.grid*row*math.sin(PI3)

  94.         num_col = args.dimension-abs(row)

  95.         cxr = cx-.5*args.grid*(num_col-1.0)

  96.         for col in range(num_col):

  97.             HOLES += '<circle cx="%.2f" cy="%.2f" r="%.2f"/>\n' % (cxr+col*args.grid, cyr, args.radius)

  98. 

  99. def draw_disc(cx, cy, layer):

  100.     global HOLES, SHAPES, MARKS

  101.     turtle       = svgturtle.SvgTurtle(cx, cy)

  102.     turtle.penup()

  103.     turtle.forward(args.disc_radius)

  104.     turtle.pendown()

  105.     turtle.left(90)

  106.     turtle.circle(args.disc_radius)

  107.     turtle.penup()

  108.     turtle.home()

  109.     if layer=='disc':

  110.         HOLES += '<path d="%s"/>\n' % turtle.to_s()

  111.     else:

  112.         MARKS += '<path d="%s"/>\n' % turtle.to_s()

  113. 

  114. def draw_plane(cx, cy, layer):

  115.     global HOLES, SHAPES, MARKS

  116.     if layer=='interior':

  117.         edge = args.interior_edge

  118.     elif layer=='opening':

  119.         edge = args.opening_edge

  120.     elif layer=='plug' or layer=='plug_mark':

  121.         edge = args.plug_edge

  122.     else:

  123.         edge = args.exterior_edge

  124.     turtle       = svgturtle.SvgTurtle(cx, cy)

  125.     turtle.penup()

  126.     if layer=='plug_mark':

  127.         turtle.right(30)

  128.     turtle.forward(edge)

  129.     turtle.right(120)

  130.     if layer=='interior':

  131.         turtle.forward(args.corner_inset)

  132.         turtle.pendown()

  133.         for side in range(5):

  134.             turtle.forward(args.interior_leg)

  135.             turtle.left(90)

  136.             turtle.forward(args.thickness)

  137.             turtle.right(90)

  138.             turtle.forward(args.horizontal_finger+args.kerf)

  139.             turtle.right(90)

  140.             turtle.forward(args.thickness)

  141.             turtle.left(90)

  142.             turtle.forward(args.interior_leg)

  143.             turtle.circle(-args.corner_radius, 60)

  144.         turtle.forward(edge-2.0*args.corner_inset)

  145.         turtle.circle(-args.corner_radius, 60)

  146.     elif layer=='plug' or layer=='plug_mark':

  147.         turtle.pendown()

  148.         for side in range(3):

  149.             turtle.forward(0.5*edge)

  150.             turtle.right(90)

  151.             turtle.circle(0.5*edge, 120)

  152.             turtle.right(90)

  153.             turtle.forward(0.5*edge)

  154.             turtle.right(60)

  155.     else:

  156.         turtle.pendown()

  157.         for side in range(6):

  158.             turtle.forward(edge)

  159.             turtle.right(60)

  160.     if layer=='plug':

  161.         HOLES += '<path d="%s"/>\n' % turtle.to_s()

  162.     elif layer=='plug_mark':

  163.         MARKS += '<path d="%s"/>\n' % turtle.to_s()

  164.     else:

  165.         SHAPES += '<path d="%s"/>\n' % turtle.to_s()

  166.     turtle.reset()

  167.     turtle.penup()

  168.     if layer=='bottom' or layer=='rim':

  169.         turtle.forward(args.interior_edge)

  170.         turtle.right(120)

  171.         turtle.forward(args.corner_inset)

  172.         for side in range(5):

  173.             for finger in range(args.n_hor_fingers):

  174.                 turtle.forward(args.exterior_leg if finger == 0 else args.horizontal_finger+args.kerf)

  175.                 turtle.pendown()

  176.                 turtle.left(90)

  177.                 turtle.forward(args.thickness)

  178.                 turtle.right(90)

  179.                 turtle.forward(args.horizontal_finger-args.kerf)

  180.                 turtle.right(90)

  181.                 turtle.forward(args.thickness)

  182.                 turtle.right(90)

  183.                 turtle.forward(args.horizontal_finger-args.kerf)

  184.                 turtle.penup()

  185.                 turtle.right(180)

  186.                 turtle.forward(args.horizontal_finger-args.kerf)

  187.             turtle.forward(args.exterior_leg)

  188.             turtle.pendown()

  189.             turtle.left(90)

  190.             turtle.forward(args.thickness)

  191.             turtle.right(90)

  192.             turtle.circle(-args.corner_radius-args.thickness, 60)

  193.             turtle.right(90)

  194.             turtle.forward(args.thickness)

  195.             turtle.right(90)

  196.             turtle.circle(args.corner_radius, 60)

  197.             turtle.penup()

  198.             turtle.right(180)

  199.             turtle.circle(-args.corner_radius, 60)

  200.         turtle.forward(args.interior_edge-2*args.corner_inset)

  201.         turtle.pendown()

  202.         turtle.left(90)

  203.         turtle.forward(args.thickness)

  204.         turtle.right(90)

  205.         turtle.circle(-args.corner_radius-args.thickness, 60)

  206.         turtle.right(90)

  207.         turtle.forward(args.thickness)

  208.         turtle.right(90)

  209.         turtle.circle(args.corner_radius, 60)

  210.         HOLES += '<path d="%s"/>\n' % turtle.to_s()

  211. 

  212. def draw_flex(t, h):

  213.     global HOLES

  214.     turtle = svgturtle.SvgTurtle(t.x, t.y)

  215.     gap    = args.flex_gap*args.thickness

  216.     ncut   = max(int((h-gap) // (args.flex_cut*args.thickness)), 1)

  217.     cut    = ((h-gap) / ncut) - gap

  218.     dx     = args.flex_width*args.thickness

  219.     nlines = int(args.corner // dx)

  220.     x0     = .5*(args.corner - (nlines-1)*dx)

  221. 

  222.     turtle.forward(x0)

  223.     for line in range(nlines):

  224.         turtle.pendown()

  225.         if (line % 2) == 0:

  226.             turtle.right(90)

  227.             turtle.forward(gap+cut)

  228.             for section in range(ncut-2):

  229.                 turtle.penup()

  230.                 turtle.forward(gap)

  231.                 turtle.pendown()

  232.                 turtle.forward(gap+2*cut)

  233.             turtle.penup()

  234.             turtle.forward(gap)

  235.             if (ncut % 2) == 0:

  236.                 turtle.pendown()

  237.                 turtle.forward(gap+cut)

  238.                 turtle.penup()

  239.             turtle.left(90)

  240.         else:

  241.             turtle.left(90)

  242.             if (ncut % 2) == 1:

  243.                 turtle.forward(gap+cut)

  244.             for section in range(ncut-1-(ncut % 2)):

  245.                 turtle.penup()

  246.                 turtle.forward(gap)

  247.                 turtle.pendown()

  248.                 turtle.forward(gap+2*cut)

  249.             turtle.penup()

  250.             turtle.forward(gap)

  251.             turtle.right(90)

  252.         turtle.forward(dx)

  253.     HOLES += '<path d="%s"/>\n' % turtle.to_s()

  254. 

  255. def draw_case_h(turtle, h, top):

  256.     turtle.forward(0.5*args.interior_edge-0.5*args.corner)

  257.     for side in range(6):

  258.         turtle.left(90)

  259.         turtle.forward(args.thickness)

  260.         turtle.right(90)

  261.         if top:

  262.             draw_flex(turtle, h+2*args.thickness)

  263.         turtle.forward(args.corner)

  264.         turtle.right(90)

  265.         turtle.forward(args.thickness)

  266.         turtle.left(90)

  267.         if side == 5:

  268.             break

  269.         turtle.forward(args.wall_leg-0.5*args.kerf)

  270.         for finger in range(args.n_hor_fingers):

  271.             if finger > 0:

  272.                 turtle.forward(args.horizontal_finger-args.kerf)

  273.             turtle.left(90)

  274.             turtle.forward(args.thickness)

  275.             turtle.right(90)

  276.             turtle.forward(args.horizontal_finger+args.kerf)

  277.             turtle.right(90)

  278.             turtle.forward(args.thickness)

  279.             turtle.left(90)

  280.         turtle.forward(args.wall_leg-0.5*args.kerf)

  281.     turtle.forward(0.5*args.interior_edge-0.5*args.corner)

  282. 

  283. def draw_case_v(turtle, h):

  284.     ey = turtle.y+h

  285.     leg = (h-(args.n_ver_fingers-0.66)*args.vertical_finger)/2.0

  286.     slope = args.vertical_finger/math.sqrt(18)

  287.     turtle.forward(leg)

  288.     for finger in range(args.n_ver_fingers):

  289.         ty = ey if finger==args.n_ver_fingers-1 else turtle.y+args.vertical_finger

  290.         turtle.circle(args.tooth, 135)

  291.         turtle.forward(slope)

  292.         turtle.circle(-args.tooth, 135)

  293.         turtle.forward(0.66*args.vertical_finger)

  294.         turtle.circle(-args.tooth, 135)

  295.         turtle.forward(slope)

  296.         turtle.circle(args.tooth, 135)

  297.         turtle.forward(ty-turtle.y)

  298. 

  299. def draw_case(x0, y0, h, slots):

  300.     global HOLES, SHAPES

  301.     turtle = svgturtle.SvgTurtle(x0, y0+args.thickness)

  302.     draw_case_h(turtle, h, True)

  303.     turtle.right(90)

  304.     draw_case_v(turtle, h)

  305.     turtle.right(90)

  306.     draw_case_h(turtle, h, False)

  307.     turtle.penup()

  308.     turtle.left(90)

  309.     turtle.back(h)

  310.     turtle.pendown()

  311.     draw_case_v(turtle, h)

  312.     SHAPES += '<path d="%s"/>\n' % turtle.to_s()

  313.     for slot in slots:

  314.         for side in range(5):

  315.             x = x0+(side+.5)*args.interior_edge+args.exterior_slot

  316.             y = y0+slot

  317.             w = args.horizontal_finger-args.kerf

  318.             h = args.thickness-args.kerf

  319.             HOLES += '<rect x="%.2f" y="%.2f" width="%.2f" height="%.2f"/>\n' % (x, y, w, h)

  320. 

  321. print('<svg viewBox="0 0 %.2f %.2f" width="%.2fmm" height="%.2fmm" stroke-width="0.1" xmlns="http://www.w3.org/2000/svg">' % (DIMX, DIMY, DIMX, DIMY))

  322. draw_grid(0.5*BOX, 0.5*BOX)

  323. draw_plane(0.5*BOX, 0.5*BOX, 'interior')

  324. draw_grid(1.5*BOX, 0.5*BOX)

  325. draw_plane(1.5*BOX, 0.5*BOX, 'interior')

  326. draw_plane(0.5*BOX, 1.5*BOX, 'bottom')

  327. draw_plane(1.5*BOX, 1.5*BOX, 'rim')

  328. draw_plane(1.5*BOX, 1.5*BOX, 'opening')

  329. draw_disc(1.5*BOX, 1.5*BOX, 'disc')

  330. draw_plane(2.5*BOX, 0.5*BOX, 'plug')

  331. draw_plane(2.5*BOX, 1.5*BOX, 'lid')

  332. draw_plane(2.5*BOX, 1.5*BOX, 'plug_mark')

  333. draw_disc(2.5*BOX, 1.5*BOX, 'disc_mark')

  334. draw_case(0.05*args.grid*args.dimension, 2.0*BOX, args.height+args.extra_height+args.thickness, args.slots)

  335. print('<g fill="none" stroke="black">', SHAPES, '</g>', '<g fill="none" stroke="red">', HOLES, '</g>', '<g fill="none" stroke="blue">', MARKS, '</g>', sep='\n')

  336. print('</svg>')