crystalballer/Baller.scad

use <inserts.scad>
use <threads.scad>


$fa = ($preview) ? 12 : 1;
$fs = ($preview) ?  2 : 1;
$incolor = true;

// Config
BallDiameter  = 65;
BallClearance = 2;
BallSealWidth = 3;
PlateLip      = 2;
PlateDiameter = BallDiameter + 2*(BallClearance + BallSealWidth + PlateLip);
PlateThick    = BallSealWidth/2 + 1;

//plate_full();
PlateSep = 0;
pd = PlateDiameter+PlateSep;
pt = PlateThick;
echo("PD=", pd);
translate([pd+5,0]) plate_top(thickness=pt);
translate([0,pd+5]) plate_mid(thickness=pt);
translate([pd+5,pd+5]) cap_compression(PlateDiameter, pt);
translate([-(pd+5),0]) mold_wall(PlateDiameter, pt, BallDiameter);
translate([0,-(pd+5)]) plate_under();

module stack(pt, ed=10 ,expand=false) {
	d = expand ? pt + ed : pt+.01;
	for (i = [0:$children-1]) {
		translate([0,0,d*i]) children(i);
	}
}

module mold_wall(pd, pt, bd, sd=4, wt=3) {
	threadc = $incolor ? "green" : undef;
	ptol = 2;
	wh = bd/2+pt+sd;
	difference() {
		union() {
			translate([0,0,2]) cylinder(d=pd, h=wh);
			color(threadc) metric_thread(
				diameter=pd+ptol,
				length=4.01,
				internal=false);
		}
		translate([0,0,-.1]) 
			cylinder(d1=pd-wt, d2=pd-wt-3, h=wh+4+.2);
	}
		
}

module cap_compression(pd, pt, th=7, wt=3, register=true, key=true) {
	td=pd+2;
	difference() {
		cylinder(d=td+wt, h=th);
		translate([0,0,-.01]) cylinder(d=3, h=5);
		translate([0,0,-.01]) cylinder(d=6, h=3);
		translate([0,0,2*pt]) metric_thread(diameter=td,length=th+.01, internal=true);
		if (register && ! key)
			translate([0,0,2*pt]) register_seal();
			
	}
	if (register && key)
		translate([0,0,2*pt]) register_seal();
}

module plate(
	d=PlateDiameter,
	thickness = PlateThick)
{
	translate([0,0,-thickness])
		cylinder(d=d, h=thickness+.01);
}

module plate_mid(thickness  = 1) {
	translate([0,0,thickness]) { 
		ball(bottom=false);
		plate(thickness=thickness);
		register_seal();
	}
}

module plate_top(thickness  = 1) {
	translate([0,0,thickness]) { 
		ball(bottom=false);
		difference() {
			plate(thickness=thickness);
			register_seal();
		}
	}
}

module plate_under(thickness  = 1) {
	translate([0,0,thickness]) { 
		underball();
		plate(thickness=thickness);
		register_seal();
	}
}


module ball(
	bd=BallDiameter,
	insert=true,
	top = true, 
	bottom = true) 
{
	insertc = $incolor ? "gold" : undef;
	maxz = top ? bd/2 : 0;
	minz = bottom ? -bd/2 : 0;
	echo("maxz:", maxz);
	echo("minz:", minz);
	difference() {
		intersection() {
			sphere(d=bd);
			translate([0,0,(maxz+minz)/2])
				cube([bd, bd, maxz-minz],center=true);
		}
		color(insertc) { 
			if (insert) for (iz = [-bd/2, bd/2]) {
				rot = (iz < 0) ? 180 : 0;
				translate([0,0,iz]) 
					rotate([0,rot,0])
						thread_insertM25($die=true);
			}
			if (! bottom) 
				rotate([0,0,0]) 
					thread_insertM25($die=true);
		}
	}
}

module register_seal(
	bd  = BallDiameter,
	cl  = BallClearance,  // Clearance around ball
	sw  = BallSealWidth,  // Width of register
	) 
{
	rotate_extrude()
		translate([bd/2+cl,0,0])
			circle(d=sw);
	
}

module underball() {
	intersection() {
		translate([0,0,9]) { 
			rotate_extrude(angle=360) 
				translate([10+15/2,0,0])
					circle(d=20);
			translate([0,0,-4]) 
				cylinder(d=55, h=10, center=true);
		}
		cylinder(d=70,h=35);
	}
}