Initial copy stand design

2026-08-22 11:31:10 -07:00
commit 58a6344731
66 changed files with 2668740 additions and 0 deletions
@@ -0,0 +1,90 @@
+#!/usr/bin/env ruby
+# frozen_string_literal: true
+
+require "fileutils"
+require "open3"
+
+ROOT = File.expand_path(__dir__)
+SCAD = File.join(ROOT, "copy_stand.scad")
+OPENSCAD = ENV.fetch("OPENSCAD", "openscad")
+PYTHON = ENV.fetch("PYTHON", "python3")
+EXPORT_3MF = File.join(ROOT, "exports", "3mf")
+EXPORT_STL = File.join(ROOT, "exports", "stl")
+COMPONENT_3MF = File.join(EXPORT_3MF, "components")
+COMPONENT_STL = File.join(EXPORT_STL, "components")
+
+def run!(*command)
+  puts command.join(" ")
+  output, status = Open3.capture2e(*command)
+  puts output unless output.empty?
+  raise "Command failed: #{command.join(' ')}" unless status.success?
+end
+
+def export(part, directory, extension)
+  output = File.join(directory, "#{part}.#{extension}")
+  return output if ENV["REBUILD"] != "1" && File.size?(output)
+
+  run!(OPENSCAD, "-o", output, "-D", %(part="#{part}"), SCAD)
+  output
+end
+
+def export_segment(part, index, directory, extension)
+  output = File.join(directory, "#{part}_#{index}.#{extension}")
+  return output if ENV["REBUILD"] != "1" && File.size?(output)
+
+  run!(OPENSCAD, "-o", output, "-D", %(part="#{part}"),
+       "-D", "segment_index=#{index}", SCAD)
+  output
+end
+
+def package(output, title, bases, accents = [])
+  command = [
+    PYTHON, File.join(ROOT, "tools", "package_multimaterial_3mf.py"),
+    output, "--title", title
+  ]
+  bases.each { |path| command.concat(["--base", path]) }
+  accents.each { |path| command.concat(["--accent", path]) }
+  run!(*command)
+end
+
+FileUtils.mkdir_p([EXPORT_3MF, EXPORT_STL, COMPONENT_3MF, COMPONENT_STL])
+
+%w[base_accent socket coupon coupon_black coupon_key coupon_accent].each do |part|
+  export(part, EXPORT_3MF, "3mf")
+end
+
+%w[socket coupon coupon_key].each do |part|
+  export(part, EXPORT_STL, "stl")
+end
+
+base_segments = (0..5).map do |index|
+  export_segment("base_segment", index, COMPONENT_3MF, "3mf")
+end
+black_segments = (0..5).map do |index|
+  export_segment("base_black_segment", index, COMPONENT_3MF, "3mf")
+end
+
+package(File.join(EXPORT_3MF, "base.3mf"), "Copy Stand Base - Single Color",
+        base_segments)
+package(File.join(EXPORT_3MF, "base_black.3mf"), "Copy Stand Base - Black Mesh",
+        black_segments)
+package(File.join(EXPORT_3MF, "base_multicolor.3mf"), "Copy Stand Base",
+        black_segments, [File.join(EXPORT_3MF, "base_accent.3mf")])
+
+package(File.join(EXPORT_3MF, "coupon_multicolor.3mf"),
+        "Copy Stand Calibration Coupon",
+        [File.join(EXPORT_3MF, "coupon_black.3mf"),
+         File.join(EXPORT_3MF, "coupon_key.3mf")],
+        [File.join(EXPORT_3MF, "coupon_accent.3mf")])
+
+# A multi-solid ASCII STL fallback avoids forcing OpenSCAD/CGAL to union the
+# large stepped base in one expensive operation. Slicers merge the touching
+# solids at slice time.
+segment_stls = (0..5).map do |index|
+  export_segment("base_segment", index, COMPONENT_STL, "stl")
+end
+File.open(File.join(EXPORT_STL, "base.stl"), "wb") do |combined|
+  segment_stls.each { |path| combined.write(File.binread(path)) }
+end
+
+puts "Exports written to #{File.join(ROOT, 'exports')}"