Updated solid base creation logic

* Simplified.
* More readable.
* Prevents gaps that could be left by old logic. (rounded_square)

gridfinity-rebuilt-baseplate.scad

@@ -341,7 +341,7 @@ module square_baseplate_lip(height=0, size = l_grid) {
 
     corner_center_distance = size/2 - BASEPLATE_OUTSIDE_RADIUS;
 
-    render(convexity = 2) // Fixes ghosting in preview
+    //render(convexity = 2) // Fixes ghosting in preview
     union() {
         baseplate_lip(height, size, size);
         pattern_circular(4)

gridfinity-spiral-vase.scad

@@ -88,7 +88,7 @@ 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*+BASE_OUTSIDE_RADIUS;
+d_fo1 = 2*+BASE_TOP_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;
@@ -171,7 +171,7 @@ 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], BASE_OUTSIDE_RADIUS+0.001, center=true);
+            rounded_square([l_grid-0.5-0.005, l_grid-0.5-0.005, h_base*10], BASE_TOP_RADIUS+0.001, center=true);
         }
         translate([0,0,0.01])
         difference() {
@@ -239,7 +239,7 @@ 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, BASE_OUTSIDE_RADIUS, center=true);
+            rounded_square(l_grid-o-0.05, BASE_TOP_RADIUS, center=true);
         }
     }
 }

src/core/gridfinity-rebuilt-utility.scad

@@ -217,12 +217,12 @@ module cut_move(x, y, w, h) {
 // ===== Modules ===== //
 
 /**
- *@summary Create the base of a gridfinity bin, or use it for a custom object.
+ * @brief Create the base of a gridfinity bin, or use it for a custom object.
  * @param grid_size Number of bases in each dimension. [x, y]
  * @param grid_dimensions [length, width] of a single Gridfinity base.
  * @param thumbscrew Enable "gridfinity-refined" thumbscrew hole in the center of each base unit. This is a ISO Metric Profile, 15.0mm size, M15x1.5 designation.
  */
-module gridfinityBase(grid_size, grid_dimensions=[l_grid, l_grid], hole_options=bundle_hole_options(), off=0, final_cut=true, only_corners=false, thumbscrew=false) {
+module gridfinityBase(grid_size, grid_dimensions=GRID_DIMENSIONS_MM, hole_options=bundle_hole_options(), off=0, final_cut=true, only_corners=false, thumbscrew=false) {
     assert(is_list(grid_dimensions) && len(grid_dimensions) == 2 &&
         grid_dimensions.x > 0 && grid_dimensions.y > 0);
     assert(is_list(grid_size) && len(grid_size) == 2 &&
@@ -235,7 +235,7 @@ module gridfinityBase(grid_size, grid_dimensions=[l_grid, l_grid], hole_options=
 
     // Per spec, there's a 0.5mm gap between each base.
     // This must be kept constant or half bins may not work correctly.
-    gap_mm = l_grid - BASE_SIZE;
+    gap_mm = GRID_DIMENSIONS_MM - BASE_TOP_DIMENSIONS;
 
     // Divisions per grid
     // Normal, half, or quarter grid sizes supported.
@@ -249,22 +249,26 @@ module gridfinityBase(grid_size, grid_dimensions=[l_grid, l_grid], hole_options=
     final_grid_size = [grid_size.x * divisions_per_grid.x, grid_size.y * divisions_per_grid.y];
 
     base_center_distance_mm = [grid_dimensions.x / divisions_per_grid.x, grid_dimensions.y / divisions_per_grid.y];
-    individual_base_size_mm = [base_center_distance_mm.x - gap_mm, base_center_distance_mm.y - gap_mm];
+    individual_base_size_mm = [base_center_distance_mm.x, base_center_distance_mm.y] - gap_mm;
 
     // Final size of the base top. In mm.
     // subtracting gap_mm here to remove an outer lip along the peremiter.
     grid_size_mm = [
-        base_center_distance_mm.x * final_grid_size.x - gap_mm,
+        base_center_distance_mm.x * final_grid_size.x,
-        base_center_distance_mm.y * final_grid_size.y - gap_mm
+        base_center_distance_mm.y * final_grid_size.y
-    ];
+    ] - gap_mm;
 
     // Top which ties all bases together
     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);
+        rounded_square([grid_size_mm.x, grid_size_mm.y, h_bot], BASE_TOP_RADIUS, center=true);
     }
 
     if(only_corners) {
+        hole_position = foreach_add(
+            grid_size_mm/2,
+            - HOLE_DISTANCE_FROM_BOTTOM_EDGE - BASE_PROFILE_MAX.x
+        );
         difference(){
             pattern_linear(final_grid_size.x, final_grid_size.y, base_center_distance_mm.x, base_center_distance_mm.y)
             block_base(bundle_hole_options(), 0, individual_base_size_mm, thumbscrew=thumbscrew);
@@ -272,8 +276,8 @@ module gridfinityBase(grid_size, grid_dimensions=[l_grid, l_grid], hole_options=
             copy_mirror([0, 1, 0]) {
                 copy_mirror([1, 0, 0]) {
                     translate([
-                        grid_size_mm.x/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE - BASE_PROFILE_MAX.x,
+                        hole_position.x,
-                        grid_size_mm.y/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE - BASE_PROFILE_MAX.x,
+                        hole_position.y,
                         0
                     ])
                     block_base_hole(hole_options, off);
@@ -287,31 +291,38 @@ module gridfinityBase(grid_size, grid_dimensions=[l_grid, l_grid], hole_options=
     }
 }
 
+/**
+ * @brief Solid polygon of a gridfinity base.
+ * @details Ready for use with `sweep_rounded(...)`.
+ */
+module base_polygon() {
+    translated_line = foreach_add(BASE_PROFILE, [BASE_BOTTOM_RADIUS, 0]);
+    solid_profile = concat(translated_line,
+        [
+            [0, BASE_PROFILE_MAX.y],  // Go in to form a solid polygon
+            [0, 0],  // Needed since start has been translated.
+        ]
+    );
+    polygon(solid_profile);
+}
+
 /**
  * @brief A single Gridfinity base.  With holes (if set).
  * @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!
+ * @param top_dimensions [x, y] size of a single base.  Only set if deviating from the standard!
  * @param thumbscrew Enable "gridfinity-refined" thumbscrew hole in the center of each base unit. This is a ISO Metric Profile, 15.0mm size, M15x1.5 designation.
  */
-module block_base(hole_options, off=0, size=[BASE_SIZE, BASE_SIZE], thumbscrew=false) {
+module block_base(hole_options, off=0, top_dimensions=BASE_TOP_DIMENSIONS, thumbscrew=false) {
-    assert(
+    assert(is_list(top_dimensions) && len(top_dimensions) == 2);
-        is_list(size) &&
+    assert(is_bool(thumbscrew));
-        len(size) == 2 &&
-        is_bool(thumbscrew)
-    );
 
-    // How far, in the +x direction,
+    base_bottom = base_bottom_dimensions(top_dimensions);
-    // the profile needs to be from it's [0, 0] point
+    sweep_inner = foreach_add(base_bottom, -2*BASE_BOTTOM_RADIUS);
-    // such that when swept by 90 degrees to produce a corner,
+    cube_size = foreach_add(base_bottom, -BASE_BOTTOM_RADIUS);
-    // 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];
+    assert(sweep_inner.x > 0 && sweep_inner.y > 0,
-    base_profile_size = size - outer_diameter;
+        str("Minimum size of a single base must be greater than ", 2*BASE_TOP_RADIUS)
-    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)
     );
 
     thumbscrew_outerdiam = 15;
@@ -324,19 +335,11 @@ module block_base(hole_options, off=0, size=[BASE_SIZE, BASE_SIZE], thumbscrew=f
     render(convexity = 2)
     difference() {
         union(){
-            sweep_rounded(base_profile_size)
+            sweep_rounded(sweep_inner)
-            translate([translation_x, 0, 0])
+                base_polygon();
-            polygon(BASE_PROFILE);
 
-            rounded_square(
+            translate([0, 0, BASE_PROFILE_MAX.y/2])
-                [
+            cube([cube_size.x, cube_size.y, BASE_PROFILE_MAX.y], center=true);
-                    base_bottom_size.x + TOLLERANCE,
-                    base_bottom_size.y + TOLLERANCE,
-                    BASE_PROFILE_MAX.y
-                ],
-                translation_x,
-                center=true
-            );
         }
 
         if (thumbscrew) {
@@ -357,8 +360,8 @@ module block_base(hole_options, off=0, size=[BASE_SIZE, BASE_SIZE], thumbscrew=f
             j = sign(sin(a+1));
             i = sign(cos(a+1));
             translate([
-                i * (base_bottom_size.x/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
+                i * (base_bottom.x/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
-                j * (base_bottom_size.y/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
+                j * (base_bottom.y/2 - HOLE_DISTANCE_FROM_BOTTOM_EDGE),
                 0])
             rotate([0, 0, a])
             block_base_hole(hole_options, off);

src/core/standard.scad

@@ -3,9 +3,16 @@
 r_c1 = 0.8;
 // bottom thiccness of bin
 h_bot = 2.2;
-// length of a grid unit
-l_grid = 42;
 
+/**
+ * @brief Size of a single gridfinity unit. [Length, Width] In millimeters.
+ */
+GRID_DIMENSIONS_MM = [42, 42];
+
+/**
+ * @deprecated Use GRID_DIMENSIONS_MM instead.
+ */
+l_grid = GRID_DIMENSIONS_MM.x;
 
 // Outside rounded radius of bin
 // Per spec, matches radius of upper base section.
@@ -96,8 +103,9 @@ STACKING_LIP_SUPPORT_HEIGHT = 1.2;
 
 /**
  * @Summary Stacking lip as defined in the spec.  No support.
+ * @Details This is just a line, and will not create a solid polygon.
  */
-RAW_STACKING_LIP = [
+STACKING_LIP_LINE = [
     [0, 0], // Inner tip
     [0.7, 0.7], // Go out 45 degrees
     [0.7, (0.7+1.8)], // Vertical increase
@@ -110,7 +118,7 @@ RAW_STACKING_LIP = [
  *               Including wall thickness.
  *          "y": The height of the stacking lip.
  */
-STACKING_LIP_SIZE = RAW_STACKING_LIP[3];
+STACKING_LIP_SIZE = STACKING_LIP_LINE[3];
 
 _stacking_lip_support_angle = 45;
 
@@ -123,40 +131,69 @@ _stacking_lip_support_height_mm =
     + tan(90 - _stacking_lip_support_angle) * STACKING_LIP_SIZE.x;
 
 /**
- * @Summary Stacking lip with a support.
+ * @Summary Stacking lip with a support. Used to create a polygon.
  * @Details Support is so the stacking lip is not floating in mid air when wall width is less than stacking lip depth.
  */
-STACKING_LIP = concat(RAW_STACKING_LIP, [
+STACKING_LIP = concat(STACKING_LIP_LINE, [
     [STACKING_LIP_SIZE.x, -_stacking_lip_support_height_mm], // Down to support bottom
     [0, -STACKING_LIP_SUPPORT_HEIGHT], // Up and in (to bottom inner support)
-    [0, 0] // Close the shape. Technically not needed.
+    //[0, 0] // Implicit back to start
 ]);
 
 // ****************************************
 // Base constants
 // Based on https://gridfinity.xyz/specification/
 // ****************************************
-BASE_OUTSIDE_RADIUS = r_base;
 
+/**
+ * @Summary Profile of a Gridfinity base as described in the spec.
+ * @Details This is just a line, and will not create a solid polygon.
+ */
 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
+    [(0.8+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.
+/**
+ * @Summary Corner radius of the top of the base.
+ */
+BASE_TOP_RADIUS = r_base;
+
+/**
+ * @Summary Size of the top of the base. [Length, Width]
+ * @Details Each unit's base is 41.5mm x 41.5mm
+ *          Leaving 0.5mm gap with an l_grid of 42
+ */
+BASE_TOP_DIMENSIONS = [41.5, 41.5];
+
+/**
+ * @Summary 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
+ * @Summary Corner radius of the bottom of the base.
-BASE_SIZE = 41.5;
+ * @Details This is also how much BASE_PROFILE needs to be translated
+ *          to use `sweep_rounded(...)`.
+ */
+BASE_BOTTOM_RADIUS = BASE_TOP_RADIUS - BASE_PROFILE_MAX.x;
 
+/**
+ * @Summary Dimensions of the bottom of the base. [Length, Width]
+ * @Details Supports arbitrary top sizes.
+ * @param top_dimensions [Length, Width] of the top of the base.
+ */
+function base_bottom_dimensions(top_dimensions = BASE_TOP_DIMENSIONS) =
+    assert(is_list(top_dimensions) && len(top_dimensions) == 2
+        && is_num(top_dimensions.x) && is_num(top_dimensions.y))
+    [top_dimensions.x - 2*BASE_PROFILE_MAX.x,
+    top_dimensions.y - 2*BASE_PROFILE_MAX.x];
 
 /**
  * @summary Height of the raw base
+ * @Deprecated
  */
 h_base = BASE_PROFILE_MAX.y;
 
@@ -174,7 +211,7 @@ BASEPLATE_LIP = [
     [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
+    //[0, 0] // Implicit back to start
 ];
 
 // Height of the baseplate lip.