E5-Microswiss-Spider/coolingFanDuct.scad

/* mount options */
wt = 2; // wall thickness (min 5mm for m2 inserts)
bpt = 7; // thickness of base plate
rd = 4 ; //inner radius of fan duct bend
wo = 25; // width of opening

zofsmnt = 5; // vertical distance between bottom of fan and bottom of base plate
xhbl = 22; // distance in x from fan to heat block
yhbl = -15.5; // distance in y from fan center to center of nozzle (negative to base plate)
zhbl = 27.2; // distance in z from fan to heat block underside
zbed = 6.5; // how far does the nozzle protrude out of the heat block?
xhbln = 11.5; // distance from heat block to nozzle center
zgap = 2.5; // gap left to bed/part
xgap = 4; // gap from duct to heat block


/* fan size */
wtfm = 5; // wall thickness fan mount
lf  = 40; // length
tf  = 10; // thickness
lhf = 34.8; // distance mounting holes
lof = 28; // length of outlet
wof = 8; // width of outlet
rc = 2; // radius corners


$fn= 100;


/* calculations */
ho = zbed-zgap-wt; // height of opening in duct tip

a = atan(zbed/(xhbln+xgap));
b = 90 - a;

vtb = sin(b) * rd; // vertical travel achieved in bend
htb = rd - (cos(b) * rd); // horizontal travel achieved in bend

xad = xhbl+((tf-wof)/2)-xgap-htb-wt;
zad = xad*tan(a);
lad = xad/cos(a);
lav = zhbl-vtb-zad;

xto = (2*wt)+wof > tf ? (2*wt)+wof : tf;
xo = xto>tf? wt : (tf-wof)/2;
xm = xto>tf?xto -(tf-wof)/2-0.01:tf-0.01;
y = lf+bpt;//+ bpt;
yo = (lf-lof)/2;
yb = lf/2-yhbl+wo/2>y-wt? y-wt-wo:lf/2-yhbl-wo/2 < wt? wt:lf/2-yhbl-wo/2;  //(y-wo)/2;

yba = lf/2-yhbl+wo/2>y-wt? y-2*wt-wo:lf/2-yhbl-wo/2 < wt? 0:lf/2-yhbl-wo/2-wt;  //(y-wo)/2;
ybo = (lf-lof)/2-wt;

posxad = htb+xto;
poszad = -zhbl+zad;

module through(l=7, lh=2, lt=1, lb=1){
    union(){
        translate([0,0,l-lh])cylinder(h=lh+lt, d=4.2);
        translate([0,0,-lb])cylinder(h=l+lh+lb, d=2.5);
    }
}

module m3 (h=8, lt=1){
    //translate([0,0,-lt])cylinder(h, d=2.5); // tapped M3
    translate([0,0,-lt])cylinder(h, d=4); // rutex insert
}

module m2 (h=8, lt=1){
    translate([0,0,-lt])cylinder(h, d=1.5); // tapped M3
    //translate([0,0,-lt])cylinder(h, d=3.2); // rutex insert
}

module mount(){
    translate([4,4,-12])difference(){
        hull(){
            translate([0,0,6])cylinder(h=6, d=8);
            translate([4,-4,0])cube([0.01,8,12]);
        }
        translate([0,0,12])mirror([0,0,1])through(l=10,lb=1,lt=1,lh=7);
    }
}

difference(){
    union(){
        translate([posxad,0,poszad])hull(){
            rotate([0,a,0])translate([-0.01,ybo,-xto])cube([0.01,y-ybo,xto]);
            rotate([0,a,0])translate([-0.01+lad,yba,-1*ho-2*wt])cube([0.01,y-yba,ho+2*wt]);
        }
        translate([xto+rd,ybo,-lav])rotate([-90,a+90,0])rotate_extrude(angle=b){
            translate([rd,0])square([xto,y-ybo]);
        }
        hull(){
            translate([0,0,-2*wtfm])cube([xto,y,2*wtfm]);
            translate([0,ybo,-lav])cube([xto,y-ybo,0.01]);
        //translate([0,0,-lav])cube([xto,y,lav]);
        }
        translate([xm,0,-2*wtfm])hull(){
            cube([0.01,lf-0.4,wtfm*2]);
            translate([wtfm,0,wtfm])cube([0.01,lf-0.4,wtfm]);
        }
    }
    translate([xo,yo, -lav-0.01])cube([wof,lof,lav+1]);
    translate([xto+rd,yo,-lav])rotate([-90,a+90,0])rotate_extrude(angle=b){
        translate([rd+xo,0])square([wof,lof]);
    }
    translate([posxad,0,poszad])hull(){
        rotate([0,a,0])translate([-0.01,yo,-wof-xo])cube([0.01,lof,wof]);
        rotate([0,a,0])translate([lad,yb,-ho-wt])cube([0.01,wo,ho]);
    }

    for(y=[8,lf-8])translate([xm+wtfm/2,y,0])mirror([0,0,1])through(l=wtfm,lt=wtfm);
    translate([xto/2,y-bpt/2,-zofsmnt])mirror([0,0,1])through(l=wtfm,lt=zhbl);
    translate([-1,y-bpt-0.4,-zofsmnt])cube([xto*2,bpt+1,zofsmnt+1]);

    // cut view

 //translate([-1,-1,-zhbl-zbed])cube([xto+xhbl+2,lf/2,zhbl+zbed+5]);
}