Parametric Aluminum Extrusion Module

Extrusions.py

from math import sqrt
from FreeCAD import Base

#Main class for general extrusion related methods
class ExtrusionProfile():
    def __init__(self, profile):
        self.profile = profile

    def makeExtrusion(self, p1, p2, rotateAngle=0):
        """Generates an extrusion which connects between two points, 
          points represent the center of the face of each end
          profile is a filled face, and p1,p2 are Vectors representing points in 3D space
          rotateAngle specifies the amount to rotate about the extrusion axis after orienting the face"""
        dir = p2.sub(p1)
        normal = Base.Vector(0,0,1) # current assumed normal of profile face (restricted to the XY plane)
        cross = dir.cross(normal)
        angle = math.degrees(dir.getAngle(normal))
        profile = self.profile.copy()
        profile.translate(p1)
        if cross.x != 0 or cross.y !=0 or cross.z != 0:
            profile.rotate(p1, cross, -angle)
        extrusion = profile.extrude(dir)
        extrusion.rotate(p1, dir, rotateAngle)
        return extrusion

# A simple profile that mimics the extrusion type used in default MendelMax
class BasicExtrusionProfile(ExtrusionProfile):
    def __init__(self, size=20.0, edgeThickness=2.0, diagonalThickness=1.5, slotWidth=6.0, centerBore=4.2, centerWidth=8.0):
        s2 = size / 2.0
        sw2 = slotWidth / 2.0
        cw2 = centerWidth / 2.0
        dt2 = sqrt(2.0) * diagonalThickness / 2.0
        # define 1/8 of the points, this works similarly to Midpoint circle algorithm taking advantage of all the symmetry in the extrusion face to avoid hardcoding many point values
        points = [ 
            Base.Vector(cw2, cw2 - dt2),
            Base.Vector(s2 - edgeThickness, s2 - (edgeThickness + dt2)),
            Base.Vector(s2 - edgeThickness, sw2),
            Base.Vector(s2, sw2)
        ]
        # symmetry across "y = x"
        mirror = [Base.Vector(p.y, p.x) for p in reversed(points)]
        points.append(Base.Vector(size/2.0, size/2.0)) # corner point
        points.extend(mirror)

        points.extend([Base.Vector(-p.x, p.y) for p in reversed(points)]) # X axis symmetry
        points.extend([Base.Vector(p.x, -p.y) for p in reversed(points)]) # Y axis symmetry
    
        # convert list of vertices to a face
        face = Part.makeFilledFace(Part.makePolygon(points).Edges)
    
       # cut out the circle
        c = Part.makeCircle(centerBore / 2.0)
        c = Part.makeFilledFace(c.Edges)
        face = face.cut(c) 
        
        self.profile = face
    
# Solid square bar(for use in boolean cut operations)
class SolidSquareExtrusionProfile(ExtrusionProfile):
    def __init__(self, size=20.0):
        s2 = size / 2.0
        poly = Part.makePolygon([
            Base.Vector(s2,s2), 
            Base.Vector(-s2,s2), 
            Base.Vector(-s2,-s2), 
            Base.Vector(s2,-s2)
        ])
        self.profile = Part.makeFilledFace(poly.Edges)



class MendelMax():
    ExtrusionProfiles = {    
        "2020": { # similar dimensions to a commonly used vendor. Don't su mi!
            'size': 20.0,
            'edgeThickness': 2.0,
            'diagonalThickness': 1.5,
            'slotWidth': 6.0,
            'centerBore': 4.2,
            'centerWidth': 8.0,
        }
    }
    
    def __init__(self, extrusion_profile="2020", extrusion_x_length=300.0, extrusion_y_length=340.0 , extrusion_diagonal_length=420.0):
        self.extrusion_profile = BasicExtrusionProfile(MendelMax.ExtrusionProfiles[extrusion_profile])
        self.extrusion_x_length = extrusion_x_length
        self.extrusion_y_length = extrusion_y_length
        self.extrusion_diagonal_length = extrusion_diagonal_length

        #generated dimensions
        self.extrusion_x_top_length = extrusion_x_length + 120.0
        #Extrusion lengths aren't exactly the same as the lengths of the triangle geometry that defines the frame angle
        #self.triangle_diagonal_length = self.extrusion_diagonal_length + 


    def makeInPlaceExtrusions(self):
        self.extrusion_profile 





profile = BasicExtrusionProfile()
x = profile.makeExtrusion(Base.Vector(0,0,0), Base.Vector(0,0,30))
Part.show(x)

cutterProfile = SolidSquareExtrusionProfile(10)
y = cutterProfile.makeExtrusion(Base.Vector(-30, 0, 10),Base.Vector(30, 0, 10) )
Part.show(y)
#x = x.cut(y)  # not sure why this line doesn't work. FreeCAD bug?
#Part.show(x)