From 416c3a93aa840c706233b684d1ed80d96de81179 Mon Sep 17 00:00:00 2001
From: =?UTF-8?q?Thea=20Sch=C3=B6bl?= <dev@theaninova.de>
Date: Sat, 24 Feb 2024 21:11:09 +0100
Subject: [PATCH] feat: endcap improvements

---
 README.md  | 14 ++++++++++----
 track.scad | 56 +++++++++++++++++++++++++++++++++---------------------
 2 files changed, 44 insertions(+), 26 deletions(-)

diff --git a/README.md b/README.md
index ed35590..7aec7a0 100644
--- a/README.md
+++ b/README.md
@@ -1,4 +1,4 @@
-# Parametric Monorail
+# Brick Monorail
 
 ## Design differences
 
@@ -14,11 +14,17 @@ _These are 3d printing optimized, compatible rails, not replicas. Replicas print
 
 ## Printing
 
-To be compatible with standard bricks, the following print settings are recommended
+To be compatible with standard bricks, the following print settings are strongly advised
 
 - Nozzle: 0.4, this is equivalent to 1 LDU.
-- Layer height: 0.1, though 0.2 will also do. Refrain from using 0.15, since that does not cleanly divides the LDU.
-- Supports: Tree (normal supports may print faster, but lead to way worse results. But ymmv).
+- Layer height: Ideally 0.1, though 0.2 will also do. Refrain from using 0.15, since that does not cleanly divides the LDU.
+  - Make sure your initial layer height is either 0.2 or 0.4!
+- Enable Bridge Settings in Cura
+- Supports: **none**. These parts are designed to be printed without any supports, though some of the bridging is not exactly
+  what you would call easy for the printer, so be on the lookout.
+- Make sure you set your "Initial Layer Horizontal Expansion" to a value that works for you, for example -0.2mm to
+  compensate for elephant's foot. Better overcompensate here, if you don't do this you might not be able to fit
+  bricks in the slot!
 
 My prints were done on a modified SecKit SK-Go2 running Klipper, with 10k acceleration and 150mm/s print speed for a good
 balance of speed and quality. A short rail will take about an hour to print.
diff --git a/track.scad b/track.scad
index c3912b8..df832fb 100644
--- a/track.scad
+++ b/track.scad
@@ -1,6 +1,7 @@
 include <lib/BOSL/shapes.scad>;
 include <lib/BOSL/transforms.scad>;
 include <lib/BOSL/constants.scad>;
+include <lib/BOSL/beziers.scad>;
 
 $LDU=0.4;
 
@@ -55,50 +56,51 @@ module brickSlot(w=1, l=1, h=3) {
     mirror_copy([0, 1, 0])
     translate([$tile / 2, $tile / 2, 0])
     cyl(d=$fillet, h=$plate * h, align=V_DOWN, $fn=12);
-  difference () {
-    cuboid([$stud+2*$LDU, $stud+2*$LDU, $studHeight], align=V_TOP);
-    mirror_copy([1, -1, 0])
-      mirror_copy([1, 0, 0])
-      translate([$stud / 2, 0, 0])
-      cyl(d=2*$LDU, h=$studHeight, align=V_TOP+V_RIGHT, $fn=12);
-  }
-  mirror_copy([1, 0, 0])
-    mirror_copy([0, 1, 0])
-    translate([$stud/2+$LDU, $stud/2+$LDU, 0])
-    cyl(d=$fillet, h=$studHeight, align=V_TOP, $fn=12);
+  cuboid([$stud, $stud, $studHeight * 2], align=V_TOP);
 }
 
-module endCap() {
+module endCapStraight() {
   $width = $baseWidth - $plate * 2;
   union() {
     difference() {
       union() {
         cuboid([$width, $tile * 2, $tile], edges=EDGE_BOT_FR+EDGE_BOT_RT+EDGE_BOT_LF);
-        mirror_copy([0, 1, 0])
-          translate([0, $tile / 2, 0])
-          cyl(l=$width + $studHeight * 2, d=$stud, orient=ORIENT_X, $fn=24);
+        difference() {
+          mirror_copy([0, 1, 0])
+            translate([0, $tile / 2, 0])
+            cyl(l=$width + $studHeight * 2, d=$stud, orient=ORIENT_X, $fn=24);
+          mirror_copy([1, 0, 0])
+            translate([$tile * 2, 0, -$stud / 2])
+            rotate([0, -14, 0])
+            cuboid([$studHeight * 10, $tile * 4, $LDU * 2], align=V_TOP+V_LEFT);
+        }
 
         translate([$tile, -$tile, 0]) cuboid([8 * $LDU, $LDU, $tile], align=V_RIGHT+V_FRONT);
       }
+      // Fingernail slot
       mirror_copy([1, 0, 0])
-        mirror_copy([0, 1, 0])
-        translate([$width / 2, $tile / 2, 0])
-        torus(d2=$edgeTolerance, d=$stud, orient=ORIENT_X, $fn=24);
+        translate([$width / 2, 0, $tile / 2])
+        cuboid([$LDU, $tile, $LDU])
 
       translate([$plate, $tile / 2, $tile - $LDU]) cube([$LDU, $tile, $LDU]);
       translate([$width + $plate - $LDU, $tile / 2, $tile - $LDU]) cube([$LDU, $tile, $LDU]);
-  
+
+      // Brick slots
       mirror_copy([1, 0, 0])
-        translate([$tile / 2, -$tile / 2, $tile / 2 - $plate])
+        translate([$tile / 2, -$tile / 2, $tile / 2 - $plate * 2])
         brickSlot();
+      // Bridging improvements
+      translate([0, 0, $tile / 2 - $plate * 2]) cuboid([$tile * 2, $tile - 4 * $LDU, $LDU], align=V_FRONT);
+      translate([0, -4 * $LDU, $tile / 2 - $plate * 2]) cuboid([$tile * 2, $stud, $LDU * 2], align=V_FRONT);
 
-
+      // End Slots
       translate([-$tile, -$tile, 0]) cuboid([8 * $LDU, $LDU, $tile], align=V_LEFT+V_BACK);
       place_copies([[-$tile, -$tile + $LDU], [$tile + 8 * $LDU, -$tile, 0]])
         mirror_copy([1, 0, 0], cp=[-4 * $LDU, 0, 0])
         cyl(d=$fillet, h=$tile, $fn=12);
     }
 
+    // Rail
     translate([0, $teethTolerance / 2, $tile / 2]) cuboid([$teethRailWidth, $tile * 2 - $teethTolerance, $plate], align=V_TOP);
     translate([0, -$tile, $tile / 2]) group() {
       for (i = [0:(2 * $teeth - 1)]) {
@@ -108,5 +110,15 @@ module endCap() {
   }
 }
 
+module curve90(r=12) {
+  translate([r * $tile, $tile, 0]) endCapStraight();
+  translate([$tile, r * $tile, 0]) rotate(-90) endCapStraight();
+  //ir = ($r 
+  path = [[2 * $tile, r * $tile, 0], [r * $tile / 2, r * $tile, 0], [r * $tile, r * $tile / 2, 0], [r * $tile,  2 * $tile, 0]];
+  extrude_2d_shapes_along_bezier(path) {
+    circle(r=10);
+  }
+}
 
-endCap();
+//curve90();
+endCapStraight();