Calibration Boxes.scad

## Calibration Boxes.scad
// Simple calibration boxes
//  Thin wall open box - verify Extrusion Multiplier
//  Solid box - verify infill settings
// Ed Nisley - KE4ZNU
// http://softsolder.com/

Layout = "Open";					// Open Solid

Texting = "";				// text message on solid box or empty string to suppress

//-------
//- Extrusion parameters must match reality!

ThreadThick = 0.25;
ThreadWidth = 0.40;

Protrusion = 0.1;           // make holes end cleanly

function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

//-------
// Dimensions

WallThick = 3.0 * ThreadWidth;
echo(str("Wall thickness: ",WallThick));

BoxSize = 40.0;
echo(str("Overall size: ",BoxSize));

NominalHeight = 3.0;
echo(str("Nominal height: ",NominalHeight));

Height = IntegerMultiple(NominalHeight,ThreadThick);
echo(str("Actual height: ",Height));

Rotation = 0;								// 45 to exercise X and Y axis motors at same time

CornerRadius = max(2.0, 2.0 + WallThick);
CornerSides = 8*4;

//--------

module Solid() {

	difference() {
		hull()
			for (i=[-1,1], j=[-1,1])
				translate([i*(BoxSize - 2*CornerRadius)/2,j*(BoxSize - 2*CornerRadius)/2,0])
					cylinder(r=CornerRadius,h=Height,$fn=CornerSides);
		if (len(Texting))
			translate([0,0,-Protrusion/2])
				linear_extrude(height=3*ThreadThick + Protrusion)
					mirror([1,0,0])
						text(text=Texting,size=6,spacing=1.05,font="ITC Zapf Chancery:style=Italic",halign="center",valign="center");
	}
}


module Thinwall() {
	difference() {
		Solid();
		hull()
			for (i=[-1,1], j=[-1,1])
				translate([i*(BoxSize - 2*CornerRadius)/2,j*(BoxSize - 2*CornerRadius)/2,-Protrusion])
					cylinder(r=(CornerRadius - WallThick),h=(Height + 2*Protrusion),$fn=CornerSides);
	}
}


//-------

rotate(Rotation)
	if (Layout == "Open")
		Thinwall();
	else
		Solid();