Define the profile of the base by sweeping a polygon.

This is the same approach taken for the stacking lip and baseplate.

gridfinity-rebuilt-utility.scad

@@ -199,44 +199,56 @@ module cut_move(x, y, w, h) {
 
 // ===== Modules ===== //
 
-module profile_base() {
+/**
-    polygon([
+ *@summary Create the base of a gridfinity bin, or use it for a custom object.
-        [0,0],
+ * @param length X,Y size of a single Gridfinity base.
-        [0,h_base],
+ */
-        [r_base,h_base],
+module gridfinityBase(gx, gy, length, dx, dy, hole_options=bundle_hole_options(), off=0, final_cut=true, only_corners=false) {
-        [r_base-r_c2,h_base-r_c2],
+    assert(
-        [r_base-r_c2,r_c1],
+        is_num(gx) &&
-        [r_base-r_c2-r_c1,0]
+        is_num(gy) &&
-    ]);
+        is_num(length) &&
-}
+        is_num(dx) &&
+        is_num(dy) &&
+        is_bool(final_cut) &&
+        is_bool(only_corners)
+    );
 
-module gridfinityBase(gx, gy, l, dx, dy, hole_options=bundle_hole_options(), off=0, final_cut=true, only_corners=false) {
     dbnxt = [for (i=[1:5]) if (abs(gx*i)%1 < 0.001 || abs(gx*i)%1 > 0.999) i];
     dbnyt = [for (i=[1:5]) if (abs(gy*i)%1 < 0.001 || abs(gy*i)%1 > 0.999) i];
-    dbnx = 1/(dx==0 ? len(dbnxt) > 0 ? dbnxt[0] : 1 : round(dx));
+    dbnx = 1/(dx != 0 ? round(dx) : (len(dbnxt) > 0 ? dbnxt[0] : 1));
-    dbny = 1/(dy==0 ? len(dbnyt) > 0 ? dbnyt[0] : 1 : round(dy));
+    dbny = 1/(dy != 0 ? round(dy) : (len(dbnyt) > 0 ? dbnyt[0] : 1));
-    xx = gx*l-0.5;
-    yy = gy*l-0.5;
 
-    if (final_cut)
+    // Final size in number of bases
-    translate([0,0,h_base])
+    grid_size = [gx/dbnx, gy/dbny];
-    rounded_rectangle(xx+0.002, yy+0.002, h_bot/1.5, r_fo1+0.001);
 
-    intersection(){
+    // Per spec, there's a 0.5mm gap between each base,
-        if (final_cut)
+    // But that needs to be scaled based on everything else.
-        translate([0,0,-1])
+    individual_base_size_mm = [dbnx, dbny] * BASE_SIZE;
-        rounded_rectangle(xx+0.005, yy+0.005, h_base+h_bot/2*10, r_fo1+0.001);
+    base_center_distance_mm = [dbnx, dbny] * length;
+    gap_mm = base_center_distance_mm - individual_base_size_mm;
+
+    // Final size of the base top. In mm.
+    grid_size_mm = [
+        base_center_distance_mm.x * grid_size.x,
+        base_center_distance_mm.y * grid_size.y,
+    ] - gap_mm;
+
+    if (final_cut) {
+        translate([0, 0, h_base-TOLLERANCE])
+        rounded_square([grid_size_mm.x, grid_size_mm.y, h_bot], BASE_OUTSIDE_RADIUS, center=true);
+    }
 
     if(only_corners) {
         difference(){
-                pattern_linear(gx/dbnx, gy/dbny, dbnx*l, dbny*l)
+            pattern_linear(grid_size.x, grid_size.y, base_center_distance_mm.x, base_center_distance_mm.y)
-                block_base(gx, gy, l, dbnx, dbny, bundle_hole_options(), off);
+            block_base(bundle_hole_options(), 0, individual_base_size_mm);
 
             copy_mirror([0, 1, 0]) {
                 copy_mirror([1, 0, 0]) {
                     translate([
-                            (gx/2)*l_grid - d_hole_from_side,
+                        grid_size_mm.x/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE - BASE_PROFILE_MAX.x,
-                            (gy/2) * l_grid - d_hole_from_side,
+                        grid_size_mm.y/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE - BASE_PROFILE_MAX.x,
                         0
                     ])
                     block_base_hole(hole_options, off);
@@ -245,57 +257,64 @@ module gridfinityBase(gx, gy, l, dx, dy, hole_options=bundle_hole_options(), off
         }
     }
     else {
-            pattern_linear(gx/dbnx, gy/dbny, dbnx*l, dbny*l)
+        pattern_linear(grid_size.x, grid_size.y, base_center_distance_mm.x, base_center_distance_mm.y)
-            block_base(gx, gy, l, dbnx, dbny, hole_options, off);
+        block_base(hole_options, off, individual_base_size_mm);
-        }
     }
 }
 
 /**
  * @brief A single Gridfinity base.  With holes (if set).
- * @param gx
- * @param gy
- * @param l
- * @param dbnx
- * @param dbny
  * @param hole_options @see block_base_hole.hole_options
  * @param off
+ * @param size [x, y] size of a single base.  Only set if deviating from the standard!
  */
-module block_base(gx, gy, l, dbnx, dbny, hole_options, off) {
+module block_base(hole_options, off=0, size=[BASE_SIZE, BASE_SIZE]) {
+    assert(is_list(size) && len(size) == 2);
+
+    // How far, in the +x direction,
+    // the profile 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 = BASE_OUTSIDE_RADIUS - BASE_PROFILE_MAX.x;
+
+    outer_diameter = [2*BASE_OUTSIDE_RADIUS, 2*BASE_OUTSIDE_RADIUS];
+    base_profile_size = size - outer_diameter;
+    base_bottom_size = base_profile_size + [2*translation_x, 2*translation_x];
+    assert(base_profile_size.x > 0 && base_profile_size.y > 0,
+        str("Minimum size of a single base must be greater than ", outer_diameter)
+    );
+
     render(convexity = 2)
     difference() {
-        block_base_solid(dbnx, dbny, l, off);
-
-        pattern_circular(abs(l-d_hole_from_side/2)<0.001?1:4)
-        translate([l/2-d_hole_from_side, l/2-d_hole_from_side, 0])
-        block_base_hole(hole_options, off);
-    }
-}
-
-/**
- * @brief A gridfinity base with no holes.
- * @details Used as the "base" with holes removed from it later.
- * @param dbnx
- * @param dbny
- * @param l
- * @param o
- */
-module block_base_solid(dbnx, dbny, l, o) {
-    xx = dbnx*l-0.05;
-    yy = dbny*l-0.05;
-    oo = (o/2)*(sqrt(2)-1);
-    translate([0,0,h_base])
-    mirror([0,0,1])
         union() {
-        hull() {
+            sweep_rounded(base_profile_size.x, base_profile_size.y)
-            rounded_rectangle(xx-2*r_c2-2*r_c1+o, yy-2*r_c2-2*r_c1+o, h_base+oo, r_fo3);
+            translate([translation_x, 0, 0])
-            rounded_rectangle(xx-2*r_c2+o, yy-2*r_c2+o, h_base-r_c1+oo, r_fo2);
+            polygon(BASE_PROFILE);
+
+            rounded_square(
+                [
+                    base_bottom_size.x + TOLLERANCE,
+                    base_bottom_size.y + TOLLERANCE,
+                    BASE_PROFILE_MAX.y
+                ],
+                translation_x,
+                center=true
+            );
         }
-        translate([0,0,oo])
+
-        hull() {
+        // 4 holes
-            rounded_rectangle(xx-2*r_c2+o, yy-2*r_c2+o, r_c2, r_fo2);
+        // Need this fancy code to support refined holes and non-square bases.
-            mirror([0,0,1])
+        for(a=[0:90:270]){
-            rounded_rectangle(xx+o, yy+o, h_bot/2+abs(10*o), r_fo1);
+            // i and j represent the 4 quadrants.
+            // The +1 is used to keep any values from being exactly 0.
+            j = sign(sin(a+1));
+            i = sign(cos(a+1));
+            translate([
+                i * (base_bottom_size.x/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
+                j * (base_bottom_size.y/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
+                0])
+            rotate([0, 0, a])
+            block_base_hole(hole_options, off);
         }
     }
 }

gridfinity-spiral-vase.scad

@@ -72,13 +72,20 @@ else gridfinityVase(); // Generate the bin
 
 // ===== CONSTRUCTION ===== //
 
+//Deprecated Variables
+r_fo2 = 3.2 / 2;  // outside radii 2
+r_fo3 = 1.6 / 2;  // outside radii 3
+r_c2 = 2.4; // upper base chamfer "radius"
+d_hole = 26;  // center-to-center distance between holes
+//End Deprecated Variables
+
 d_bottom = layer*(max(bottom_layer,1));
 x_l = l_grid/2;
 
 dht = (gridz_define==0)?gridz*7 : (gridz_define==1)?h_bot+gridz+h_base : gridz-(enable_lip?3.8:0);
 d_height = (enable_zsnap?((abs(dht)%7==0)?dht:dht+7-abs(dht)%7):dht)-h_base;
 
-d_fo1 = 2*r_fo1;
+d_fo1 = 2*+BASE_OUTSIDE_RADIUS;
 
 f2c = sqrt(2)*(sqrt(2)-1); // fillet to chamfer ratio
 me = ((gridx*l_grid-0.5)/n_divx)-nozzle*4-d_fo1-12.7-4;
@@ -161,7 +168,7 @@ module gridfinityBaseVase() {
         intersection() {
             block_base_blank(0);
             translate([0,0,-h_base-1])
-            rounded_square([l_grid-0.5-0.005, l_grid-0.5-0.005, h_base*10], r_fo1+0.001, center=true);
+            rounded_square([l_grid-0.5-0.005, l_grid-0.5-0.005, h_base*10], BASE_OUTSIDE_RADIUS+0.001, center=true);
         }
         translate([0,0,0.01])
         difference() {
@@ -229,7 +236,7 @@ module block_base_blank(o = 0) {
             rounded_square(l_grid-o-0.05-2*r_c2, r_fo2, center=true);
             mirror([0,0,1])
             linear_extrude(d_bottom)
-            rounded_square(l_grid-o-0.05, r_fo1, center=true);
+            rounded_square(l_grid-o-0.05, BASE_OUTSIDE_RADIUS, center=true);
         }
     }
 }

standard.scad

@@ -1,25 +1,15 @@
 
-// height of the base
-h_base = 5;
 // lower base chamfer "radius"
 r_c1 = 0.8;
-// upper base chamfer "radius"
-r_c2 = 2.4;
 // bottom thiccness of bin
 h_bot = 2.2;
-// outside radii 1
-r_fo1 = 7.5 / 2;
-// outside radii 2
-r_fo2 = 3.2 / 2;
-// outside radii 3
-r_fo3 = 1.6 / 2;
 // length of a grid unit
 l_grid = 42;
 
 
 // Outside rounded radius of bin
 // Per spec, matches radius of upper base section.
-r_base = r_fo1;
+r_base = 7.5 / 2;
 
 // Tollerance to make sure cuts don't leave a sliver behind,
 // and that items are properly connected to each other.
@@ -35,11 +25,12 @@ SCREW_HOLE_RADIUS = 3 / 2;
 MAGNET_HOLE_RADIUS = 6.5 / 2;
 MAGNET_HOLE_DEPTH = MAGNET_HEIGHT + (LAYER_HEIGHT * 2);
 
-// center-to-center distance between holes
-d_hole = 26;
 // distance of hole from side of bin
 d_hole_from_side=8;
 
+// Based on https://gridfinity.xyz/specification/
+HOLE_DISTANCE_FROM_BOTTOM_EDGE = 4.8;
+
 // Meassured diameter in Fusion360.
 // Smaller than the magnet to keep it squeezed.
 REFINED_HOLE_RADIUS = 5.86 / 2;
@@ -62,6 +53,7 @@ CHAMFER_ANGLE = 45;
 BASEPLATE_SCREW_COUNTERSINK_ADDITIONAL_RADIUS = 5/2;
 BASEPLATE_SCREW_COUNTERBORE_RADIUS = 5.5/2;
 BASEPLATE_SCREW_COUNTERBORE_HEIGHT = 3;
+
 // ****************************************
 
 // top edge fillet radius
@@ -109,6 +101,34 @@ stacking_lip_support_wall_height_mm = 1.2;
 stacking_lip_support_height_mm =
     stacking_lip_support_wall_height_mm + d_wall2;
 
+// ****************************************
+// Base constants
+// Based on https://gridfinity.xyz/specification/
+// ****************************************
+BASE_OUTSIDE_RADIUS = r_base;
+
+BASE_PROFILE = [
+    [0, 0], // Innermost bottom point
+    [0.8, 0.8], // Up and out at a 45 degree angle
+    [0.8, (0.8+1.8)], // Straight up
+    [(0.8+2.15), (0.8+1.8+2.15)], // Up and out at a 45 degree angle
+    [0, (0.8+1.8+2.15)], // Go in to form a solid polygon
+    [0, 0] //Back to start
+];
+
+// Maximum [x,y] values/size of the base.
+BASE_PROFILE_MAX = BASE_PROFILE[3];
+
+// Each unit's base is 41.5mm x 41.5mm
+// Leaving 0.5mm gap with an l_grid of 42
+BASE_SIZE = 41.5;
+
+
+/**
+ * @summary Height of the raw base
+ */
+h_base = BASE_PROFILE_MAX.y;
+
 // ****************************************
 // Baseplate constants
 // Based on https://gridfinity.xyz/specification/
@@ -159,8 +179,6 @@ bp_rcut_depth = 2;
 
 // ****************************************
 
-// Baseplate clearance offset
-bp_xy_clearance = 0.5;
 // radius of cutout for skeletonized baseplate
 r_skel = 2;
 // minimum baseplate thickness (when skeletonized)