Skip to content

Commit

Permalink
Rewrite that improves strength while simplifying the design.
Browse files Browse the repository at this point in the history 
- Single holder side that wraps around itself in straight lines for simplicity, performance and strength.
- Simplify top by building lines for smooth top fillet
  • Loading branch information
@Yeicor
Yeicor committed May 25, 2024
1 parent 6421304 commit 67556c7
Show file tree
Hide file tree
Showing 2 changed files with 95 additions and 148 deletions.
2 changes: 1 addition & 1 deletion .github/workflows/main.yml
View file
Original file line number Diff line number Diff line change
Expand Up @@ -39,7 +39,7 @@ jobs:
- run: "poetry install"

# Build
- run: "echo 'YACV_DISABLE_SERVER=True' >> $GITHUB_ENV && echo 'yacv_export=True' >> $GITHUB_ENV"
- run: "printf 'YACV_DISABLE_SERVER=True\nexport_yacv=True\nexport_stl=True\n' >> $GITHUB_ENV"
- run: "poetry run python main.py"
- run: "final=True poetry run python main.py"
- run: "mkdir export && mv *.glb *.stl export/"
Expand Down
241 changes: 94 additions & 147 deletions main.py
View file
Original file line number Diff line number Diff line change
Expand Up @@ -17,9 +17,9 @@
min_wall = 0.4 * MM # Minimum wall thickness on XY (common for FDM 3D printing)
wall = 3 * min_wall # 3 perimeters on XY

# Bottle parameters
# Bottle parameters (should be a perfect fit)
bottle_body_height = 215 * MM
bottle_body_radius = 8.2 / 2 * CM
bottle_body_radius = 8.0 / 2 * CM
bottle_body_fillet = 1 * CM
bottle_top_extrusion = 16 * MM
bottle_top_angle = 24 # degrees
Expand All @@ -35,25 +35,16 @@
# Holder parameters
holder_thickness = 2 * wall
holder_core_pct = 0.75 # > 0, <= 0.9
holder_side_grabber_side = 20 * MM
holder_side_grabber_max_angle = 145 # degrees
holder_side_grabber_min_angle_offset_top = -25 # degrees (also applied to 2nd, 3rd... inner grabbers)
holder_side_grabber_min_angle_offset_bottom = 0 # degrees
holder_side_grabber_smooth = 1.25 # >= 1
holder_side_grabber_count = 3 # >= 0 (slow operation, so disable if not needed while designing)
holder_side_grabber_max_angle_loss = 35 # degrees
holder_side_grabber_z_loss = holder_side_grabber_side * 1.5 # degrees
holder_bottom_grabber_min_angle = 90 # degrees
holder_bottom_grabber_side = 18 * MM
holder_bottom_grabber_side_center = holder_bottom_grabber_side * 0.65 # HACK: Helps stabilize the multisection sweep
holder_bottom_grabber_num_section_samples = [10, 8, 4] # Can cause lots of issues...
holder_bottom_grabber_max_z = bottle_body_height / 2 - holder_bottom_grabber_side / 2
holder_bottom_grabber_smooth = 1.25 # >= 1
holder_bottom_grabber_count = 3 # >= 0 (slow operation, so disable if not needed while designing)
holder_bottom_grabber_min_angle_loss = 35 # degrees
holder_bottom_grabber_z_loss = holder_bottom_grabber_side * 1.5
holder_bottom_reinforcement = 3 * MM # + holder_thickness
holder_zip_tie_hole_radius = 2.5 * MM # <= holder_thickness + bike_screw_radius * 2
holder_bottom_reinforcement = 3 * MM
holder_grabber_side = 20 * MM # Approximately...
holder_grabber_angle = 42 # degrees (of deviation from going straight down)
holder_grabber_sep = 10 * MM # Approximately...


def bb_to_box(_bb: BoundBox) -> Box:
return Box(_bb.max.X - _bb.min.X, _bb.max.Y - _bb.min.Y, _bb.max.Z - _bb.min.Z,
mode=Mode.PRIVATE).translate(_bb.center())

with BuildPart() as bottle:
with BuildSketch():
Expand All @@ -68,7 +59,7 @@
# Extrude the main profile that connects the holder and the tube
with BuildSketch(core_plane): # holder_core_profile
with Locations((bike_screw_head_height + holder_thickness, 0)):
full_profile = bottle_body_radius * 2
full_profile = (bottle_body_radius + tol) * 2
used_profile_y = full_profile * holder_core_pct
holder_core_angle = math.asin((used_profile_y / 2) / (full_profile / 2)) * 180 / math.pi
used_profile_x = full_profile / 2
Expand All @@ -87,13 +78,20 @@
extrude(amount=-holder_thickness)

# Grab the top of the bottle
with BuildSketch(
Plane(faces().group_by(Axis.Z)[-1].edges().filter_by(GeomType.CIRCLE).edge() @ 0.5, (1, 0, 0), (0, 1, 0))):
off = (bottle_top_extrusion - fillet_top_radius)
extrude_by = math.tan(math.radians(bottle_top_angle)) * off # Half to be a ramp on both sides
Rectangle(extrude_by, bottle_top_extrusion, align=(Align.MAX, Align.MIN))
chamfer(edges().group_by(Axis.X)[0].vertices().group_by(Axis.Y)[-1], off - eps, extrude_by - eps)
extrude(amount=used_profile_y / 2, both=True)
top_face_inner_edge = faces().group_by(Axis.Z)[-1].edges().filter_by(GeomType.CIRCLE).edge()
with BuildPart():
with BuildSketch(Plane(top_face_inner_edge @ 0.5, (1, 0, 0), (0, 1, 0))):
with BuildLine():
extrude_by = math.tan(math.radians(bottle_top_angle)) * bottle_top_extrusion
Polyline((0, 0), (0, bottle_top_extrusion), (-extrude_by, 0), close=True)
make_face()
del top_face_inner_edge
# extrude(amount=used_profile_y / 2, both=True)
revolve(revolution_arc=holder_core_angle)
# Perform a second revolve to align with border (simpler fillet later)
rev_axis = Axis(vertices().group_by(Axis.Y)[-1].group_by(Axis.Z)[-1].vertex().center(), (0, 0, -1))
revolve(faces().group_by(Axis.Y)[-1], axis=rev_axis, revolution_arc=holder_core_angle)
mirror()

# Add a zip tie hole in the middle of the left face, through the complete holder
with BuildSketch(core_plane.offset(bottle_height / 2).location * Plane.XZ.location):
Expand All @@ -117,141 +115,90 @@ def screw_holes(rad: float) -> Sketch:


# Now, for the hard part, design the grabber to be 3D printable wrapping around the bottle
def grabber_profile_line_fn(side: float, rad: float = bottle_body_radius + tol) -> (Curve, Vector):
with BuildLine() as _grabber_profile_line:
arc_in = RadiusArc((-side / 2, holder_thickness / 2),
(side / 2, holder_thickness / 2), rad)
arc_out = RadiusArc((-side / 2, -holder_thickness / 2),
(side / 2, -holder_thickness / 2),
rad + holder_thickness)
# Offset center to avoid slighltly overlapping bottle, which tends to cause issues
_to_center = (arc_out @ 0.5 + arc_in @ 0.5) / 2 + Vector(0, -tol, 0)
Spline(arc_in @ 1, arc_out @ 1, tangents=[arc_in % 1, -(arc_out % 1)], tangent_scalars=[2.5, 2.5])
Spline(arc_out @ 0, arc_in @ 0, tangents=[-(arc_out % 0), arc_in % 0], tangent_scalars=[2.5, 2.5])
del arc_in, arc_out
return _grabber_profile_line.line, _to_center


with BuildPart() as grabber:
# Build side grabbers
for hsg_index in range(holder_side_grabber_count):
bottom_angle_offset = holder_side_grabber_min_angle_offset_bottom if hsg_index == 0 \
else holder_side_grabber_min_angle_offset_top
grabber_lines = []
for bi_normal_off in [eps, 0]: # Build the binormal at the same time :)
with BuildLine() as grabber_line: # 3D line to be used as a reference
xyz = []
num_samples = int(bottle_height) # ~1 sample per mm
for z_index in range(num_samples + 1):
cur_holder_z_offset = holder_side_grabber_z_loss * hsg_index
z = z_index / num_samples * (bottle_height - cur_holder_z_offset * 2) + cur_holder_z_offset
max_angle = holder_side_grabber_max_angle - holder_side_grabber_max_angle_loss * hsg_index
min_angle = holder_core_angle + \
(1 - z_index / num_samples) * bottom_angle_offset + \
(z_index / num_samples) * holder_side_grabber_min_angle_offset_top
angle = max_angle - math.fabs(z_index / (num_samples / 2) - 1) ** holder_side_grabber_smooth * \
(max_angle - min_angle) + bi_normal_off
x = math.cos(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
y = math.sin(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
xyz.append((x, y, z))
Spline(*xyz)
grabber_lines.append(grabber_line.line)
del grabber_line

grabber_profile_line, to_center = grabber_profile_line_fn(side=holder_side_grabber_side)
with BuildSketch(Location(grabber_lines[0] @ 0, (0, 0, holder_core_angle + bottom_angle_offset - 90)) *
Location(-to_center)) as grabber_profile:
make_face(grabber_profile_line.edges())
del grabber_profile_line # Also used for the bottom grabber

sweep(grabber_profile.sketch, grabber_lines[0], binormal=grabber_lines[1].edge())
del grabber_lines, grabber_profile

if holder_side_grabber_count > 0:
mirror()

# Build the bottom grabber
for hbg_index in range(holder_bottom_grabber_count):
grabber_lines = []
min_angle = holder_bottom_grabber_min_angle + holder_bottom_grabber_min_angle_loss * hbg_index
for bi_normal_off in [eps, 0]: # Build the binormal at the same time :)
with BuildLine() as grabber_line: # 3D line to be used as a reference
xyz = []
num_samples = int(bottle_height) # ~1 sample per mm
for z_index in range(num_samples + 1):
angle = z_index / num_samples * (360 - 2 * min_angle) + min_angle + \
bi_normal_off * (z_index / (num_samples / 2) - 1)
max_z = holder_bottom_grabber_max_z - holder_bottom_grabber_z_loss * hbg_index
z = max_z - math.fabs(z_index / (num_samples / 2) - 1) ** holder_bottom_grabber_smooth * max_z \
+ bi_normal_off * (1 - math.fabs(z_index / (num_samples / 2) - 1))
x = math.cos(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
y = math.sin(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
xyz.append(Vector(x, y, z))
Spline(*xyz)
grabber_lines.append(grabber_line.line)
del grabber_line

sweep_sections = []
num_samples = holder_bottom_grabber_num_section_samples[hbg_index]
assert num_samples % 2 == 0, 'num_samples must be even'
for i in range(num_samples + 1):
pct = i / num_samples
flip = 1 if i < num_samples else -1
z_dir = grabber_lines[1] % pct
if i == 0 or i == num_samples:
z_dir = Vector(0, 0, 1)
binormal = (grabber_lines[0] @ pct - grabber_lines[1] @ pct).normalized()
plane = Plane(grabber_lines[1] @ pct, binormal * flip, z_dir)
roundness = (math.fabs(pct - 0.5) * 2) ** holder_bottom_grabber_smooth # Made up formula :)
size = (math.fabs(pct - 0.5) * 2) * holder_bottom_grabber_side + \
(1 - (math.fabs(pct - 0.5) * 2)) * holder_bottom_grabber_side_center
grabber_profile_line, to_center = grabber_profile_line_fn(
side=size, rad=(bottle_body_radius + tol) / (roundness + eps))
with BuildSketch(plane.location * Location(-to_center)) as grabber_profile:
make_face(grabber_profile_line.edges())
sweep_sections.append(grabber_profile.sketch)
del grabber_profile_line, grabber_profile

sweep(sweep_sections, grabber_lines[1], binormal=grabber_lines[0].edge(), multisection=True)
del grabber_lines, sweep_sections

if holder_side_grabber_count + holder_bottom_grabber_count == 0:
add(holder_core) # HACK to avoid crashing while designing


def bb_to_box(_bb: BoundBox) -> Box:
return Box(_bb.max.X - _bb.min.X, _bb.max.Y - _bb.min.Y, _bb.max.Z - _bb.min.Z).translate(_bb.center())

grabbers = [] # Boolean operations on sweeps may fail, so keep them separate
vertical_side = holder_grabber_side / math.tan(math.radians(holder_grabber_angle))
z_start_top = bottle_height - fillet_top_radius
holder_grabber_count = int(z_start_top // (vertical_side + holder_grabber_sep))
# holder_grabber_count = 0 # For performance while testing
for hsg_index in range(holder_grabber_count):
grabber_lines = []
z_start = z_start_top - hsg_index * (vertical_side + holder_grabber_sep)
num_samples = int(z_start) # ~1mm per sample (should be way more than enough as we are using splines)
z_per_step = (1 / (num_samples - 1)) * z_start
side_per_step = z_per_step * math.tan(math.radians(holder_grabber_angle))
start_angle = holder_core_angle / 2 # Clearly inside the core (to avoid overflowing corners at the top
angle_per_step = math.degrees(math.asin(side_per_step / (bottle_body_radius + tol + holder_thickness / 2)))
print('Grabber', hsg_index + 1, '/', holder_grabber_count)
for bi_normal_off in [eps, 0]: # Build the binormal at the same time :)
with BuildLine() as grabber_line: # 3D sweep path
xyz = []
for z_index in range(num_samples):
z = z_start - z_index * z_per_step
angle = start_angle + z_index * angle_per_step + bi_normal_off # Always horizontal
x = math.cos(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
y = math.sin(math.radians(angle)) * (bottle_body_radius + tol + holder_thickness / 2)
xyz.append((x, y, z))
Spline(*xyz)
grabber_lines.append(grabber_line.line)
del grabber_line

with BuildSketch(Location(grabber_lines[0] @ 0, start_angle - 90)) as grabber_profile:
with BuildLine() as grabber_profile_line:
arc_in = RadiusArc((-holder_grabber_side / 2, holder_thickness / 2),
(holder_grabber_side / 2, holder_thickness / 2), bottle_body_radius + tol)
arc_out = RadiusArc((-holder_grabber_side / 2, -holder_thickness / 2),
(holder_grabber_side / 2, -holder_thickness / 2),
bottle_body_radius + tol + holder_thickness)
# Offset center to avoid slightly overlapping bottle, which tends to cause issues
_wanted_center = (arc_out @ 0.5 + arc_in @ 0.5) / 2 + Vector(0, -tol, 0)
Spline(arc_in @ 1, arc_out @ 1, tangents=[arc_in % 1, -(arc_out % 1)], tangent_scalars=[2.5, 2.5])
Spline(arc_out @ 0, arc_in @ 0, tangents=[-(arc_out % 0), arc_in % 0], tangent_scalars=[2.5, 2.5])
del arc_in, arc_out
make_face(grabber_profile_line.line.move(Location(-_wanted_center)).edges())
del grabber_profile_line # Also used for the bottom grabber

sweep_obj = sweep(grabber_profile.sketch, grabber_lines[0], binormal=grabber_lines[1].edge(), mode=Mode.PRIVATE)
del grabber_lines, grabber_profile

print('Mirroring...')
grabbers.append(sweep_obj)
grabbers.append(mirror(sweep_obj, mode=Mode.PRIVATE))
del sweep_obj

# Final merge
bike_bottle_holder = holder_core.part + grabber.part
# - Cleaning up the merge (the grabber overflows a bit)
bb = holder_core.part.bounding_box() # Clean up the top
bb.max.X, bb.min.X, bb.max.Y, bb.min.Y = 9999, -9999, 9999, -9999
bike_bottle_holder = bike_bottle_holder & bb_to_box(bb)
bike_bottle_holder = holder_core.part # + grabber.part

# Reinforce the bottom
to_reinforce = bike_bottle_holder.faces().filter_by(Plane.XY).group_by(Axis.Z)[0] # Add bottom reinforcement
bike_bottle_holder += extrude(to_reinforce, amount=holder_bottom_reinforcement, taper=45)
to_fillet = bike_bottle_holder.edges().filter_by(Plane.XY).group_by(Axis.Z)[1]
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness)
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness) # 1

# Final fillets / chamfers
to_fillet = bike_bottle_holder.edges().filter_by(GeomType.LINE).group_by(SortBy.LENGTH)[-1].group_by(Axis.X)[-1]
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness)
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness) # 2
to_fillet = bike_bottle_holder.edges().filter_by(GeomType.LINE) \
.filter_by(Axis.Z).group_by(Axis.X)[-1].group_by(Axis.Z)[0]
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness)
to_fillet = bike_bottle_holder.edges().filter_by(GeomType.LINE).filter_by(Plane.XY).group_by(Axis.Z)[-1]
bike_bottle_holder = fillet(to_fillet, radius=fillet_top_radius)
del to_reinforce, holder_core, grabber, to_fillet # , bottle
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness) # 3
to_fillet = bike_bottle_holder.edges().group_by(Axis.Z)[-1]
bike_bottle_holder = fillet(to_fillet, radius=holder_thickness) # 4
del holder_core, to_reinforce, to_fillet # , bottle

# Assemble the grabbers, as fusing them is too slow/buggy and the slicer should be able to handle it
bike_bottle_holder = Compound([bike_bottle_holder] + grabbers)
del grabbers

if os.getenv('final'):
if os.getenv('export_stl'):
print('Exporting STL file...')
export_stl(bike_bottle_holder, 'bike-bottle-holder.stl')
else:

try:
from yacv_server import *

show_all()

if os.getenv('yacv_export'):
if os.getenv('export_yacv'):
print('Exporting YACV file...')
export_all('.', lambda name, obj: name == 'bike_bottle_holder')
except BaseException as e:
print(f'yacv_server not found or another error happened, skipping visualization: {e}')

0 comments on commit 67556c7

Please sign in to comment.