Generate Baseplate from profile isntead of as a negative

Previous implementation was off by 0.5mm,
and required creating a gridfinity base.

This is much more flexible, and easier to understand.

generic-helpers.scad

@@ -166,6 +166,8 @@ function affine_translate(vector) = [
  *        Centered on origin.
  */
 module sweep_rounded(width=10, length=10) {
+    assert(width > 0 && length > 0);
+
     half_width = width/2;
     half_length = length/2;
     path_points = [

gridfinity-rebuilt-baseplate.scad

@@ -18,9 +18,9 @@ $fs = 0.25;
 
 /* [General Settings] */
 // number of bases along x-axis
-gridx = 5;
+gridx = 1;
 // number of bases along y-axis
-gridy = 5;
+gridy = 1;
 
 /* [Screw Together Settings - Defaults work for M3 and 4-40] */
 // screw diameter
@@ -48,11 +48,11 @@ fity = 0; // [-1:0.1:1]
 /* [Styles] */
 
 // baseplate styles
-style_plate = 0; // [0: thin, 1:weighted, 2:skeletonized, 3: screw together, 4: screw together minimal]
+style_plate = 2; // [0: thin, 1:weighted, 2:skeletonized, 3: screw together, 4: screw together minimal]
 
 
 // hole styles
-style_hole = 2; // [0:none, 1:countersink, 2:counterbore]
+style_hole = 0; // [0:none, 1:countersink, 2:counterbore]
 
 /* [Magnet Hole] */
 // Baseplate will have holes for 6mm Diameter x 2mm high magnets.
@@ -69,7 +69,6 @@ hole_options = bundle_hole_options(refined_hole=false, magnet_hole=enable_magnet
 color("tomato")
 gridfinityBaseplate(gridx, gridy, l_grid, distancex, distancey, style_plate, hole_options, style_hole, fitx, fity);
 
-
 // ===== CONSTRUCTION ===== //
 
 module gridfinityBaseplate(gridx, gridy, length, dix, diy, sp, hole_options, sh, fitx, fity) {
@@ -87,44 +86,62 @@ module gridfinityBaseplate(gridx, gridy, length, dix, diy, sp, hole_options, sh,
     offsetx = dix < dx ? 0 : (gx*length-bp_xy_clearance-dix)/2*fitx*-1;
     offsety = diy < dy ? 0 : (gy*length-bp_xy_clearance-diy)/2*fity*-1;
 
+    screw_together = sp == 3 || sp == 4;
+    minimal = sp == 0 || sp == 4;
+
     difference() {
-        translate([offsetx,offsety,h_base])
-        mirror([0,0,1])
-        rounded_rectangle(dx, dy, h_base+off, r_base);
-
-        gridfinityBase(gx, gy, length, 1, 1, bundle_hole_options(), 0.5, false);
-
-        translate([offsetx,offsety,h_base-0.6])
-        rounded_rectangle(dx*2, dy*2, h_base*2, r_base);
-
         pattern_linear(gx, gy, length) {
-            render(convexity = 6) {
+            difference() {
+                if (minimal) {
+                    square_baseplate_lip(off);
+                } else {
+                    solid_square_baseplate(off);
+                }
 
-                if (sp == 1)
-                    translate([0,0,-off])
+                // Bottom/through pattern for the solid baseplates.
+                if (sp == 1) {
                     cutter_weight();
-                else if (sp == 2 || sp == 3)
-                    linear_extrude(10*(h_base+off), center = true)
+                } else if (sp == 2 || sp == 3) {
+                    translate([0,0,-TOLLERANCE])
+                    linear_extrude(off+2*TOLLERANCE)
                     profile_skeleton();
-                else if (sp == 4)
-                    translate([0,0,-5*(h_base+off)])
-                    rounded_square(length-2*r_c2-2*r_c1, 10*(h_base+off), r_fo3);
-
+                }
 
+                // Add holes to the solid baseplates.
                 hole_pattern(){
+                    // Manget hole
+                    translate([0, 0, off+TOLLERANCE])
                     mirror([0, 0, 1])
                     block_base_hole(hole_options);
 
-                    translate([0,0,-off-TOLLERANCE])
-                    if (sh == 1) cutter_countersink();
-                    else if (sh == 2) cutter_counterbore();
+                    translate([0,0,-TOLLERANCE])
+                    if (sh == 1) {
+                        cutter_countersink();
+                    } else if (sh == 2) {
+                        cutter_counterbore();
+                    }
                 }
+
             }
         }
-        screw_together = sp == 3 || sp == 4;
-        if (screw_together) cutter_screw_together(gx, gy, off);
-    }
 
+        // Round the outside corners
+        corner_center_distance = length/2;
+        copy_mirror([0, 1, 0])
+        copy_mirror([1, 0, 0])
+        translate([
+            (gx*length/2) - BASEPLATE_OUTSIDE_RADIUS,
+            (gy*length/2) - BASEPLATE_OUTSIDE_RADIUS,
+            -TOLLERANCE
+        ])
+        scale([1+TOLLERANCE, 1+TOLLERANCE, 1+2*TOLLERANCE])
+        square_baseplate_corner(off);
+
+        if (screw_together) {
+            translate([0, 0, off])
+            cutter_screw_together(gx, gy, off);
+        }
+    }
 }
 
 function calculate_offset(style_plate, enable_magnet, style_hole) =
@@ -182,20 +199,95 @@ module cutter_counterbore(){
     }
 }
 
+/**
+ * @brief Added or removed from the baseplate to square off or round the corners.
+ * @param height Baseplate's height excluding lip and clearance height.
+ */
+module square_baseplate_corner(height=0) {
+    assert(height >= 0);
+    linear_extrude(height + BASEPLATE_LIP_MAX.y)
+    difference() {
+        square(BASEPLATE_OUTSIDE_RADIUS, center=false);
+        circle(r=BASEPLATE_OUTSIDE_RADIUS-TOLLERANCE);
+    }
+}
+
+/**
+ * @brief Outer edge/lip of the baseplate.
+ * @details Includes clearance to ensure the base touches the lip
+ *          instead of the bottom.
+ * @param height Baseplate's height excluding lip and clearance height.
+ * @param width How wide a single baseplate is.  Only set if deviating from the standard!
+ * @param length How long a single baseplate is.  Only set if deviating from the standard!
+ */
+module baseplate_lip(height=0, width=l_grid, length=l_grid) {
+    assert(height >= 0);
+
+    // How far, in the +x direction,
+    // the lip needs to be from it's [0, 0] point
+    // such that when swept by 90 degrees to produce a corner,
+    // the outside edge has the desired radius.
+    translation_x = BASEPLATE_OUTSIDE_RADIUS - BASEPLATE_LIP_MAX.x;
+
+    additional_height = height + BASEPLATE_CLEARANCE_HEIGHT;
+
+    sweep_rounded(width-2*BASEPLATE_OUTSIDE_RADIUS, length-2*BASEPLATE_OUTSIDE_RADIUS)
+    translate([translation_x, additional_height, 0])
+    polygon(concat(BASEPLATE_LIP, [
+        [0, -additional_height],
+        [BASEPLATE_LIP_MAX.x, -additional_height],
+        [BASEPLATE_LIP_MAX.x, 0]
+    ]));
+}
+
+/**
+ * @brief Outer edge/lip of the baseplate, with square corners.
+ * @details Needed to prevent gaps when joining multiples together.
+ * @param height Baseplate's height excluding lip and clearance height.
+ * @param size Width/Length of a single baseplate.  Only set if deviating from the standard!
+ */
+module square_baseplate_lip(height=0, size = l_grid) {
+    assert(height >= 0 && size/2 >= BASEPLATE_OUTSIDE_RADIUS);
+    corner_center_distance = size/2 - BASEPLATE_OUTSIDE_RADIUS;
+    union() {
+        baseplate_lip(height, size, size);
+        pattern_circular(4)
+        translate([corner_center_distance, corner_center_distance, 0])
+        square_baseplate_corner(height);
+    }
+}
+
+/**
+ * @brief A single baseplate with square corners, a solid inner section, lip and the set clearance height.
+ * @param height Baseplate's height excluding lip and clearance height.
+ * @details A height of zero is the equivalent of just calling square_baseplate_lip()
+ */
+module solid_square_baseplate(height=0, length = l_grid) {
+    assert(height >= 0);
+    union() {
+        square_baseplate_lip(height, length);
+        if (height > 0) {
+            linear_extrude(height)
+            square(length - BASEPLATE_OUTSIDE_RADIUS, center=true);
+        }
+    }
+}
+
 /**
  * @brief 2d Cutter to skeletonize the baseplate.
+ * @param size Width/Length of a single baseplate.  Only set if deviating from the standard!
  * @example difference(){
  *              cube(large_number);
  *              linear_extrude(large_number+TOLLERANCE)
  *              profile_skeleton();
  *          }
  */
-module profile_skeleton() {
-    l = l_grid-2*r_c2-2*r_c1;
+module profile_skeleton(size=l_grid) {
+    l = size - 2*BASEPLATE_LIP_MAX.x;
 
     offset(r_skel)
     difference() {
-        square(l-2*r_skel+2*d_clear, center = true);
+        square(l-2*r_skel, center = true);
 
         hole_pattern()
         offset(MAGNET_HOLE_RADIUS+r_skel+2)

standard.scad

@@ -88,8 +88,11 @@ h_lip = 3.548;
 d_wall2 = r_base-r_c1-d_clear*sqrt(2);
 d_magic = -2*d_clear-2*d_wall+d_div;
 
-// Stacking Lip
+
+// ****************************************
+// Stacking Lip Constants
 // Based on https://gridfinity.xyz/specification/
+// ****************************************
 stacking_lip_inner_slope_height_mm = 0.7;
 stacking_lip_wall_height_mm = 1.8;
 stacking_lip_outer_slope_height_mm = 1.9;
@@ -106,8 +109,40 @@ stacking_lip_support_wall_height_mm = 1.2;
 stacking_lip_support_height_mm =
     stacking_lip_support_wall_height_mm + d_wall2;
 
-
+// ****************************************
 // Baseplate constants
+// Based on https://gridfinity.xyz/specification/
+// ****************************************
+BASEPLATE_OUTSIDE_RADIUS = 8 / 2;
+
+// Polygon describing the raw baseplate lip.
+// Does NOT include clearance height.
+BASEPLATE_LIP = [
+    [0, 0], // Innermost bottom point
+    [0.7, 0.7], // Up and out at a 45 degree angle
+    [0.7, (0.7+1.8)], // Straight up
+    [(0.7+2.15), (0.7+1.8+2.15)], // Up and out at a 45 degree angle
+    [(0.7+2.15), 0], // Straight down
+    [0, 0] //Back to start
+];
+
+// Height of the baseplate lip.
+// This ads clearance height to the polygon
+// that ensures the base makes contact with the baseplate lip.
+BASEPLATE_LIP_HEIGHT = 5;
+
+// The minimum height between the baseplate lip and anything below it.
+// Needed to make sure the base always makes contact with the baseplate lip.
+BASEPLATE_CLEARANCE_HEIGHT = BASEPLATE_LIP_HEIGHT - BASEPLATE_LIP[3].y;
+assert(BASEPLATE_CLEARANCE_HEIGHT > 0, "Negative clearance doesn't make sense.");
+
+// Maximum [x,y] values/size of the baseplate lip.
+// Includes clearance height!
+BASEPLATE_LIP_MAX = [BASEPLATE_LIP[3].x, BASEPLATE_LIP_HEIGHT];
+
+// ****************************************
+// Weighted Baseplate
+// ****************************************
 
 // Baseplate bottom part height (part added with weigthed=true)
 bp_h_bot = 6.4;
@@ -121,6 +156,9 @@ bp_rcut_width = 8.5;
 bp_rcut_length = 4.25;
 // Baseplate bottom cutout rounded thingy depth
 bp_rcut_depth = 2;
+
+// ****************************************
+
 // Baseplate clearance offset
 bp_xy_clearance = 0.5;
 // radius of cutout for skeletonized baseplate