// ============================================================ // Parametric MOLLE / PALS Panel Generator — SVG for laser cutting // (c) Ryan Mitchell — CC BY 4.0 (use/adapt freely with credit) // https://github.com/ryanemitchell/rmm-parametrics // ============================================================ // // QUICK START: pick a Size Preset and a Style Preset up top, press F5 // to preview (dimensions shown in mm + inches), then // File > Export > Export as SVG. The SVG is 1:1 millimetres — import // straight into XCS / LightBurn and cut. // // The two preset dropdowns combine freely (seat_back x tech_panel). // Set either to "none" to control that half manually in the Advanced // sections below. Your own presets go in user_presets.scad. // // Background: PALS is the actual grid standard (1" / 25.4 mm vertical // row pitch, 1.5" / 38.1 mm horizontal attachment pitch). "MOLLE" is // the gear system that rides on it. There is NO official standard for // rigid / laser-cut slot sizes — only the pitch is fixed. // // ============================================================ /* [Quick Controls] */ // Units for the SIZE inputs (panel width/height and quad dimensions). Everything else (slot geometry, pitches, margins, holes) stays mm - PALS is defined metrically. Presets are unaffected. units = "mm"; // [mm:Millimetres, inch:Inches] // WHAT SIZE - physical panel size/shape for common uses. The grid auto-fits whatever style you pick. "none" = use the Advanced size sections. size_preset = "none"; // [none:None - manual size below, seat_back:Seat back 290x370mm, headrest:Headrest 170x136mm, wall_600x400:Wall panel 600x400mm, pack_insert:Pack insert 240x230mm, case_insert:Case insert 155x145mm, overland_drawer:Overland drawer face 450x150mm, square_21x21:Square 21x21in (533x533mm), panel_30x20:Panel 30x20in (762x508mm), panel_24x8:Panel 24x8in (610x203mm), van_window:Van window trapezoid 750/600 x 380/320mm, seat_back_taper:Tapered seat back 320/260 x 420mm, wedge_door:Wedge door 500mm - top slants 260 to 200mm] // HOW IT'S CUT - slot geometry plus a matching feature set. "none" = use the Advanced style sections. style_preset = "none"; // [none:None - manual style below, rigid_basic:Rigid basic - 32x10mm slots + corner mount holes + rounded corners, softgoods_weave:Softgoods weave - slim staggered slits - no holes, kydex_minimal:Kydex minimal - 27x4mm slits - no holes, heavy_bars:Heavy bars - 33x14mm slots for thick steel + mount holes, tactical_square:Tactical square - square slots on 2in rows + chamfered corners + zip-tie perimeter, tech_panel:Tech panel - square slots + webbing channels between rows + corner slits + hole-slit perimeter, lightweight:Lightweight - 32x10mm slots + lightening holes + spaced mounts] // Mounting/perimeter hole diameter, mm (6 = M6 clearance-ish; 4-5 for zip ties) mount_hole_d = 6; // Beam kerf, mm. Grows the outline and shrinks slots/holes by kerf/2 each side. Leave 0 if your laser software (e.g. XCS) compensates for you. Fiber on thin steel/alu: 0.05-0.2. kerf = 0; /* [User Presets (defined in user_presets.scad)] */ // Type the name of a preset from user_presets.scad to use it instead of the size_preset dropdown custom_size_preset = ""; // Type the name of a preset from user_presets.scad to use it instead of the style_preset dropdown custom_style_preset = ""; /* [Advanced - Manual Size (size_preset = none)] */ // "rect" uses the sizes below. "quad" builds a four-sided shape from the Quad Outline section and auto-fills it with every slot that fits. outline_shape = "rect"; // [rect:Rectangle, quad:Four-sided shape (trapezoid / skewed)] // "grid": you choose columns x rows, panel size is computed. "panel": you choose panel size, max grid is fitted inside. size_mode = "grid"; // [grid:Set grid (cols x rows), panel:Set panel size (fit grid)] // Number of slot columns (grid mode) columns = 6; // Number of slot rows (grid mode) rows = 8; // Target panel width (panel mode) - in the units chosen above panel_width = 300; // Target panel height (panel mode) - in the units chosen above panel_height = 250; /* [Advanced - Quad Outline (outline_shape = quad)] */ // All five values are in the units chosen in Quick Controls. // Bottom edge length quad_bottom_width = 400; // Top edge horizontal extent quad_top_width = 300; // Height of the top-LEFT corner above the bottom edge quad_left_height = 250; // Height of the top-RIGHT corner above the bottom edge (different from left = slanted top) quad_right_height = 250; // Horizontal position of the top-left corner relative to the bottom-left corner (shifts/skews the top edge) quad_top_shift = 50; /* [Advanced - Slot Style (style_preset = none)] */ // Slot geometry. "custom" uses the values below. square_rigid also sets v_pitch to 50.8mm (2in rows - 1in slot + 1in bar, fabric-PALS analog). slot_style = "rigid_metal"; // [custom:Custom - use my slot values below, rigid_metal:Rigid metal panel - 32x10mm slots (vehicle/wall panels - straps and MALICE clips), softgoods_slim:Softgoods slim - 32x5.5mm slits (thin sheet <=2mm - tight weave), heavy_duty:Heavy duty - 33x14mm slots (thick steel - gloved-hand threading), kydex_thin:Kydex/thin sheet - 27x4mm slits (minimal look), square_rigid:Square rigid - 32x25.4mm openings on 2in row pitch (GMT-style panels)] // Slot width, mm (must clear a 1" / 25.4mm strap; keep <= h_pitch - 5 for metal) slot_width = 32; // Slot height, mm slot_height = 10; // Slot corner radius, mm (slot_height/2 = stadium / pill slots) slot_corner_radius = 3; // Slot shape word (applies to any slot style): rect, pill, hex, oval, diamond, octagon slot_shape = "rect"; // Horizontal centre-to-centre pitch, mm (PALS = 38.1) h_pitch = 38.1; // Vertical centre-to-centre pitch, mm (PALS = 25.4; square_rigid overrides to 50.8) v_pitch = 25.4; // Stagger alternate rows by half a column (half-position mounting) stagger = false; /* [Advanced - Border & Corners] */ // Minimum border between slots and panel edge, mm edge_margin = 14; // Panel corner style corner_style = "round"; // [round:Rounded, chamfer:Chamfered 45 degrees] // Corner radius / chamfer size, mm (0 = sharp corners) panel_corner_radius = 8; /* [Advanced - Mounting & Perimeter] */ mount_holes = true; // Hole centre inset from panel edge, mm mount_hole_inset = 7; // Add intermediate holes along edges when corner holes are further apart than this, mm (0 = corners only). Small values give a dense zip-tie perimeter. mount_hole_max_spacing = 200; // Short slits along the border, midway between hole positions (the alternating hole-slit perimeter on commercial panels) edge_slits = false; // Edge slit length, mm edge_slit_length = 20; // Edge slit width, mm (3-4 = zip tie, 6+ = 1in strap on edge) edge_slit_width = 3; /* [Advanced - Channels & Extras] */ // Long thin slits in the bars between slot rows - pass 1in webbing, velcro or hose clamps mid-panel (BuiltRight-style). Best with square_rigid on 50.8mm rows. inter_slits = false; // Channel slit height, mm inter_slit_h = 5; // Slot columns spanned per channel segment inter_slit_span = 3; // Bridge between channel segments, mm inter_slit_bridge = 8; // Diagonal slits just inside chamfered corners (needs corner_style = chamfer; replaces the 4 corner mounting holes) corner_slits = false; // Corner slit length, mm (0 = auto: same as the chamfer edge) corner_slit_length = 0; // Corner slit width, mm corner_slit_width = 4; // Perpendicular distance from the chamfer edge, mm corner_slit_inset = 7; // Extra holes in the bars between rows (weight reduction; weakens strap bearing - skip for heavy loads) lightening = false; lightening_style = "circle"; // [circle:Circles, hex:Hexagons] // Lightening hole size (diameter / hex across-flats), mm lightening_size = 8; /* [Advanced - Engrave Layer] */ // Label text to engrave on the panel. Export it as a SECOND SVG with output_layer=engrave and add it as an engrave operation in XCS. Empty = none. engrave_text = ""; // Text height, mm engrave_text_size = 12; // Text centre position relative to panel centre, mm engrave_text_x = 0; engrave_text_y = 0; // Which geometry this export contains. "cut" = the panel (text shown blue in preview for positioning); "engrave" = the text only. output_layer = "cut"; // [cut:Cut layer (the panel), engrave:Engrave layer (text only)] /* [Advanced - Nesting (several panels in one SVG)] */ // Copies of the panel side by side in the exported SVG (one cut job) nest_x = 1; // Copies stacked vertically nest_y = 1; // Gap between copies, mm (leave room for the kerf and part removal) nest_gap = 10; /* [Preview] */ // Show overall width/height in the preview window (mm and inches), updating live. Preview-only: automatically excluded from the exported SVG. show_dimensions = true; // Material for the weight estimate shown in the preview and console (uses the thickness below) material = "steel"; // [steel:Steel (7.85 g/cc), aluminum:Aluminum (2.70 g/cc), hdpe:HDPE (0.95 g/cc), kydex:Kydex (1.35 g/cc), none:No weight estimate] // Material thickness, mm (used for the 3D preview and the weight estimate) material_thickness = 3; // 3D preview only - MUST be false when exporting SVG preview_3d = false; /* [Hidden] */ $fn = 48; // preset tables live in separate files: built-ins in presets.scad, // yours in user_presets.scad (user entries shadow built-ins by name) include include _size_table = concat(user_size_presets, _size_presets_builtin); _style_table = concat(user_style_presets, _style_presets_builtin); _slot_table = concat(user_slot_styles, _slot_styles_builtin); // ---------- SIZE preset resolution (physical size & shape) ---------- _size_name = (custom_size_preset != "") ? custom_size_preset : size_preset; _si = search([_size_name], _size_table)[0]; assert(_size_name == "none" || _si != undef, str("Unknown size preset '", _size_name, "' - not in the dropdown list or user_presets.scad")); _sz = (_size_name == "none") ? undef : _size_table[_si]; // size presets are always panel-fit: physical size fixed, grid auto-fits the chosen style // _u converts the manual size inputs to mm when units = "inch" (preset tables are always mm) _u = (units == "inch") ? 25.4 : 1; e_size_mode = is_undef(_sz) ? size_mode : "panel"; e_panel_w = is_undef(_sz) ? panel_width * _u : _sz[1]; e_panel_h = is_undef(_sz) ? panel_height * _u : _sz[2]; e_margin = is_undef(_sz) ? edge_margin : _sz[3]; e_corner_r = is_undef(_sz) ? panel_corner_radius : _sz[4]; e_shape = is_undef(_sz) ? outline_shape : _sz[5]; e_qbw = is_undef(_sz) ? quad_bottom_width * _u : _sz[6]; e_qtw = is_undef(_sz) ? quad_top_width * _u : _sz[7]; e_qlh = is_undef(_sz) ? quad_left_height * _u : _sz[8]; e_qrh = is_undef(_sz) ? quad_right_height * _u : _sz[9]; e_qshift = is_undef(_sz) ? quad_top_shift * _u : _sz[10]; e_columns = columns; // used only in manual grid mode e_rows = rows; // ---------- STYLE preset resolution (slot geometry & features) ---------- _style_name = (custom_style_preset != "") ? custom_style_preset : style_preset; _ti = search([_style_name], _style_table)[0]; assert(_style_name == "none" || _ti != undef, str("Unknown style preset '", _style_name, "' - not in the dropdown list or user_presets.scad")); _st = (_style_name == "none") ? undef : _style_table[_ti]; e_preset = is_undef(_st) ? slot_style : _st[1]; e_stagger = is_undef(_st) ? stagger : _st[4]; e_mount = is_undef(_st) ? mount_holes : _st[5]; e_max_spc = is_undef(_st) ? mount_hole_max_spacing : _st[6]; e_edge_slits = is_undef(_st) ? edge_slits : _st[7]; e_inter = is_undef(_st) ? inter_slits : _st[8]; e_cslits = is_undef(_st) ? corner_slits : _st[9]; e_corner_sty = is_undef(_st) ? corner_style : _st[10]; e_lightening = is_undef(_st) ? lightening : _st[11]; // ---------- slot-geometry preset resolution ---------- _pi = search([e_preset], _slot_table)[0]; assert(e_preset == "custom" || _pi != undef, str("Unknown slot style '", e_preset, "' - not built-in or in user_presets.scad")); sw = (e_preset == "custom") ? slot_width : _slot_table[_pi][1]; sh = (e_preset == "custom") ? slot_height : _slot_table[_pi][2]; _scr_raw = (e_preset == "custom") ? slot_corner_radius : _slot_table[_pi][3]; scr = min(_scr_raw, sh/2, sw/2); // auto-clamped, never fatal _rec_vp = (e_preset == "custom") ? 0 : _slot_table[_pi][4]; // pitch priority: style preset > slot-style recommendation > user parameter e_h_pitch = (!is_undef(_st) && _st[2] > 0) ? _st[2] : h_pitch; e_v_pitch = (!is_undef(_st) && _st[3] > 0) ? _st[3] : (_rec_vp > 0 ? _rec_vp : v_pitch); // ---------- quad outline geometry ---------- _q_raw = [[0, 0], [e_qbw, 0], [e_qshift + e_qtw, e_qrh], [e_qshift, e_qlh]]; // BL BR TR TL (CCW) _qxs = [for (p = _q_raw) p[0]]; _qys = [for (p = _q_raw) p[1]]; _qc = [(min(_qxs) + max(_qxs))/2, (min(_qys) + max(_qys))/2]; q_pts = [for (p = _q_raw) [p[0] - _qc[0], p[1] - _qc[1]]]; // centred on origin q_w = max(_qxs) - min(_qxs); q_h = max(_qys) - min(_qys); // signed distance from point p to edge a->b (positive = inside for CCW polygon) function sdist(p, a, b) = let (dx = b[0]-a[0], dy = b[1]-a[1]) (dx*(p[1]-a[1]) - dy*(p[0]-a[0])) / sqrt(dx*dx + dy*dy); // point inside quad with clearance m from every edge function inset_ok(p, m) = min([for (i = [0:3]) sdist(p, q_pts[i], q_pts[(i+1)%4])]) >= m; // whole slot (bounding box corners) inside quad with edge_margin clearance function slot_fits(cx, cy) = min([for (c = [[cx-sw/2, cy-sh/2], [cx+sw/2, cy-sh/2], [cx+sw/2, cy+sh/2], [cx-sw/2, cy+sh/2]], i = [0:3]) sdist(c, q_pts[i], q_pts[(i+1)%4])]) >= e_margin; function _crossp(o, a, b) = (a[0]-o[0])*(b[1]-o[1]) - (a[1]-o[1])*(b[0]-o[0]); assert(e_shape != "quad" || min([for (i = [0:3]) _crossp(q_pts[i], q_pts[(i+1)%4], q_pts[(i+2)%4])]) > 0, "Quad must be convex - check widths/heights/top_shift"); // quad candidate grid (centred on bounding-box centre, filtered by slot_fits) qn_cols = max(1, floor(q_w / e_h_pitch) + 1); qn_rows = max(1, floor(q_h / e_v_pitch) + 1); function qcol_x(i) = -((qn_cols-1) * e_h_pitch)/2 + i * e_h_pitch; function qrow_y(j) = -((qn_rows-1) * e_v_pitch)/2 + j * e_v_pitch; q_slot_count = len([for (j = [0:qn_rows-1], i = [0:qn_cols-1]) if (slot_fits(qcol_x(i) + ((e_stagger && j%2==1) ? e_h_pitch/2 : 0), qrow_y(j))) 1]); // ---------- rect grid / panel dimensions ---------- fit_cols = max(1, floor((e_panel_w - 2*e_margin - sw) / e_h_pitch) + 1); fit_rows = max(1, floor((e_panel_h - 2*e_margin - sh) / e_v_pitch) + 1); n_cols = (e_size_mode == "panel") ? fit_cols : e_columns; n_rows = (e_size_mode == "panel") ? fit_rows : e_rows; grid_w = (n_cols - 1) * e_h_pitch + sw; grid_h = (n_rows - 1) * e_v_pitch + sh; p_w = (e_shape == "quad") ? q_w : ((e_size_mode == "panel") ? e_panel_w : grid_w + 2*e_margin); p_h = (e_shape == "quad") ? q_h : ((e_size_mode == "panel") ? e_panel_h : grid_h + 2*e_margin); h_bridge = e_h_pitch - sw; // material between slots in a row v_bar = e_v_pitch - sh; // material bar between rows (what straps/clips wrap) // millimetres -> inches, rounded to 2 decimals function fmt_in(v) = round(v / 25.4 * 100) / 100; // ---------- sanity checks ---------- assert(sw >= 26, str("Slot width ", sw, "mm won't clear a 25.4mm MOLLE strap")); assert(h_bridge >= 3, str("Only ", h_bridge, "mm of material between slots in a row - widen h_pitch or narrow slots")); assert(v_bar >= 6, str("Only ", v_bar, "mm bar between rows - reduce slot_height or increase v_pitch")); assert(e_shape == "quad" || (p_w >= grid_w + 2*e_margin - 0.01 && p_h >= grid_h + 2*e_margin - 0.01), "Panel too small for grid + margins"); assert(e_shape != "quad" || q_slot_count > 0, "Quad shape too small - no slots fit inside it with this margin"); assert(!e_inter || v_bar - inter_slit_h >= 4, str("Inter-row slits leave only ", (v_bar - inter_slit_h)/2, "mm webs in the ", v_bar, "mm bars - reduce inter_slit_h or use a taller v_pitch (50.8 recommended)")); if (e_cslits && !(e_corner_sty == "chamfer" && e_shape == "rect")) echo("NOTE: corner_slits need corner_style=chamfer and a rect outline - skipped"); if (e_inter && e_lightening) echo("NOTE: inter_slits and lightening both cut the bars between rows - they will overlap"); // ---------- slot count + weight estimate ---------- function shoelace(pts) = abs(sum_list([for (i = [0 : len(pts)-1]) pts[i][0]*pts[(i+1)%len(pts)][1] - pts[(i+1)%len(pts)][0]*pts[i][1]])) / 2; function sum_list(v) = len(v) == 0 ? 0 : v[0] + sum_list([for (i=[1:1:len(v)-1]) v[i]]); n_slots_total = (e_shape == "quad") ? q_slot_count : n_rows * n_cols - (e_stagger ? floor(n_rows/2) : 0); _corner_def = (e_corner_sty == "chamfer") ? 2*e_corner_r*e_corner_r : (4-PI)*e_corner_r*e_corner_r; _outline_area = (e_shape == "quad" ? shoelace(q_pts) : p_w*p_h) - _corner_def; _slot_area = sw*sh - (4-PI)*scr*scr; _ix = p_w/2 - mount_hole_inset; _iy = p_h/2 - mount_hole_inset; _n_mh = !e_mount ? 0 : 4 + 2*((e_max_spc <= 0) ? 0 : max(0, ceil(2*_ix/e_max_spc) - 1)) + 2*((e_max_spc <= 0) ? 0 : max(0, ceil(2*_iy/e_max_spc) - 1)); _n_light = !e_lightening ? 0 : max(0, (n_slots_total - n_cols)); // rough _inter_area = !e_inter || e_shape == "quad" ? 0 : (n_rows-1) * (grid_w - ceil(n_cols/inter_slit_span)*inter_slit_bridge) * inter_slit_h; _cut_area = _outline_area - n_slots_total * _slot_area - _n_mh * PI * mount_hole_d*mount_hole_d/4 - _n_light * PI * lightening_size*lightening_size/4 - _inter_area; _density = material == "steel" ? 7.85 : material == "aluminum" ? 2.70 : material == "hdpe" ? 0.95 : material == "kydex" ? 1.35 : 0; weight_g = _cut_area * material_thickness * _density / 1000; weight_str = material == "none" ? "" : str("~", weight_g >= 1000 ? str(round(weight_g/10)/100, " kg") : str(round(weight_g), " g"), " / ~", round(weight_g * 0.03527 * 10)/10, " oz (", material_thickness, "mm ", material, ")"); echo(str("=== ", n_slots_total, " slots", material == "none" ? "" : str(", est. weight ", weight_str), " ===")); // ---------- advisory warnings (non-fatal; shown in red in the preview) ---------- _shape_known = is_num(search([slot_shape], [["rect"],["pill"],["stadium"],["hex"],["hexagon"],["oval"],["ellipse"], ["round"],["diamond"],["rhombus"],["octagon"],["oct"]])[0]); warn_msgs = concat( !_shape_known ? [str("unknown slot_shape '", slot_shape, "' - using rect (try hex, oval, diamond, octagon, pill)")] : [], (slot_shape == "diamond" || slot_shape == "rhombus") ? ["diamond slots bear straps on a point - decorative use only"] : [], (_scr_raw > scr + 0.001) ? [str("slot corner radius clamped to ", scr, " mm")] : [], (h_bridge < 5) ? [str("bridge ", h_bridge, " mm between slots - thin for metal, ok for plastics")] : [], (v_bar < 8) ? [str("bar ", v_bar, " mm between rows - avoid heavy pouches")] : [], (kerf > 0.5) ? [str("kerf ", kerf, " mm is unusually large - double-check")] : [] ); for (w = warn_msgs) echo(str("WARNING: ", w)); echo(str("=== MOLLE panel", _size_name == "none" ? "" : str(" [size:", _size_name, "]"), _style_name == "none" ? "" : str(" [style:", _style_name, "]"), e_shape == "quad" ? str(" QUAD bbox ", q_w, " x ", q_h, " mm (", fmt_in(q_w), " x ", fmt_in(q_h), " in), ", q_slot_count, " slots") : str(": ", p_w, " x ", p_h, " mm (", fmt_in(p_w), " x ", fmt_in(p_h), " in), ", n_cols, " cols x ", n_rows, " rows"), ", slots ", sw, " x ", sh, " mm (pitch ", e_h_pitch, " x ", e_v_pitch, "), bar between rows ", v_bar, " mm, bridge between columns ", h_bridge, " mm", kerf > 0 ? str(", kerf comp ", kerf, " mm") : "", " ===")); // ---------- 2D primitives ---------- module rounded_rect(w, h, r) { if (r <= 0) square([w, h], center=true); else hull() for (x = [-1, 1], y = [-1, 1]) translate([x*(w/2 - r), y*(h/2 - r)]) circle(r=r); } module chamfered_rect(w, h, c) { if (c <= 0) square([w, h], center=true); else polygon([ [-w/2+c, -h/2], [w/2-c, -h/2], [w/2, -h/2+c], [w/2, h/2-c], [w/2-c, h/2], [-w/2+c, h/2], [-w/2, h/2-c], [-w/2, -h/2+c]]); } // slot cut by shape word (unknown words fall back to rect and warn) _hex_e = min(sh/2, sw/3); _oct_c = min(sh/3, sw/4); module slot() { s = slot_shape; if (s == "hex" || s == "hexagon") polygon([[-sw/2,0],[-sw/2+_hex_e,-sh/2],[sw/2-_hex_e,-sh/2], [sw/2,0],[sw/2-_hex_e,sh/2],[-sw/2+_hex_e,sh/2]]); else if (s == "oval" || s == "ellipse" || s == "round") scale([sw/2, sh/2]) circle(r=1); else if (s == "diamond" || s == "rhombus") polygon([[0,-sh/2],[sw/2,0],[0,sh/2],[-sw/2,0]]); else if (s == "octagon" || s == "oct") polygon([[-sw/2+_oct_c,-sh/2],[sw/2-_oct_c,-sh/2],[sw/2,-sh/2+_oct_c], [sw/2,sh/2-_oct_c],[sw/2-_oct_c,sh/2],[-sw/2+_oct_c,sh/2], [-sw/2,sh/2-_oct_c],[-sw/2,-sh/2+_oct_c]]); else if (s == "pill" || s == "stadium") rounded_rect(sw, sh, sh/2); else rounded_rect(sw, sh, scr); } module hexagon(af) circle(d = af / cos(30), $fn = 6); // af = across flats // ---------- rect-mode slot grid ---------- function row_y(j) = -grid_h/2 + sh/2 + j*e_v_pitch; function row_cols(j) = (e_stagger && j % 2 == 1) ? n_cols - 1 : n_cols; function col_x(i, j) = -((row_cols(j)-1)*e_h_pitch)/2 + i*e_h_pitch; module slot_grid_rect() for (j = [0 : n_rows-1], i = [0 : row_cols(j)-1]) translate([col_x(i, j), row_y(j)]) slot(); // ---------- quad-mode slot grid (auto-fill) ---------- module slot_grid_quad() for (j = [0 : qn_rows-1], i = [0 : qn_cols-1]) { x = qcol_x(i) + ((e_stagger && j%2==1) ? e_h_pitch/2 : 0); y = qrow_y(j); if (slot_fits(x, y)) translate([x, y]) slot(); } // ---------- rect-mode perimeter features ---------- function n_between(len) = (e_max_spc <= 0) ? 0 : max(0, ceil(len / e_max_spc) - 1); // corner holes need extra inset when the corner treatment cuts deeper than // the edge inset (otherwise they notch the chamfer / rounded corner) c_inset = (e_corner_r <= 0) ? mount_hole_inset : (e_corner_sty == "chamfer") ? max(mount_hole_inset, (e_corner_r + mount_hole_d/2 + 2) / 2) : max(mount_hole_inset, e_corner_r - (e_corner_r - mount_hole_d/2 - 2) / sqrt(2)); module mount_hole_set_rect() { ix = p_w/2 - mount_hole_inset; iy = p_h/2 - mount_hole_inset; nx = n_between(2*ix); ny = n_between(2*iy); // corner holes (skipped when corner slits take their place) if (!(e_cslits && e_corner_sty == "chamfer")) for (x = [-1, 1], y = [-1, 1]) translate([x*(p_w/2 - c_inset), y*(p_h/2 - c_inset)]) circle(d = mount_hole_d); if (nx > 0) for (k = [1 : nx], y = [-iy, iy]) translate([-ix + k * 2*ix/(nx+1), y]) circle(d = mount_hole_d); if (ny > 0) for (k = [1 : ny], x = [-ix, ix]) translate([x, -iy + k * 2*iy/(ny+1)]) circle(d = mount_hole_d); } module edge_slit_set_rect() { ix = p_w/2 - mount_hole_inset; iy = p_h/2 - mount_hole_inset; nx = n_between(2*ix); ny = n_between(2*iy); sx = 2*ix/(nx+1); sy = 2*iy/(ny+1); lx = min(edge_slit_length, sx - mount_hole_d - 6); // keep clear of holes ly = min(edge_slit_length, sy - mount_hole_d - 6); if (lx > 4) for (k = [0 : nx], y = [-iy, iy]) translate([-ix + (k + 0.5)*sx, y]) rounded_rect(lx, edge_slit_width, edge_slit_width/2); if (ly > 4) for (k = [0 : ny], x = [-ix, ix]) translate([x, -iy + (k + 0.5)*sy]) rounded_rect(edge_slit_width, ly, edge_slit_width/2); } // 45-degree slits just inside the chamfered corners (rect mode) module corner_slit_set() { c = e_corner_r; len = (corner_slit_length > 0) ? corner_slit_length : c * sqrt(2); for (sx = [-1, 1], sy = [-1, 1]) { mid = [sx*(p_w/2 - c/2), sy*(p_h/2 - c/2)]; // chamfer edge midpoint inw = [-sx, -sy] / sqrt(2); // inward along bisector translate(mid + inw * corner_slit_inset) rotate((sx*sy > 0) ? -45 : 45) rounded_rect(len, corner_slit_width, corner_slit_width/2); } } // long webbing/velcro channel slits in the bars between slot rows (rect mode) module inter_slit_set_rect() { for (j = [0 : n_rows-2]) { nc = min(row_cols(j), row_cols(j+1)); nseg = ceil(nc / inter_slit_span); for (s = [0 : nseg-1]) { c0 = s * inter_slit_span; c1 = min(c0 + inter_slit_span, nc) - 1; x0 = col_x(c0, j) - sw/2 + inter_slit_bridge/2; x1 = col_x(c1, j) + sw/2 - inter_slit_bridge/2; if (x1 - x0 > inter_slit_h) translate([(x0+x1)/2, row_y(j) + e_v_pitch/2]) rounded_rect(x1 - x0, inter_slit_h, inter_slit_h/2); } } } // quad version: a channel segment is kept only where slots exist above AND below it module inter_slit_set_quad() { for (j = [0 : qn_rows-2]) { nseg = ceil(qn_cols / inter_slit_span); for (s = [0 : nseg-1]) { c0 = s * inter_slit_span; c1 = min(c0 + inter_slit_span, qn_cols) - 1; ok = len([for (i = [c0 : c1]) if (!(slot_fits(qcol_x(i), qrow_y(j)) && slot_fits(qcol_x(i), qrow_y(j+1)))) 1]) == 0; x0 = qcol_x(c0) - sw/2 + inter_slit_bridge/2; x1 = qcol_x(c1) + sw/2 - inter_slit_bridge/2; if (ok && x1 - x0 > inter_slit_h) translate([(x0+x1)/2, qrow_y(j) + e_v_pitch/2]) rounded_rect(x1 - x0, inter_slit_h, inter_slit_h/2); } } } // ---------- quad-mode perimeter features (follow the slanted edges) ---------- module quad_perimeter(do_holes, do_slits) { for (i = [0 : 3]) { a = q_pts[i]; b = q_pts[(i+1) % 4]; L = norm(b - a); u = (b - a) / L; nv = [-u[1], u[0]]; // inward normal (CCW polygon) setback = max(mount_hole_inset * 2.5, e_corner_r + mount_hole_d); a2 = a + u * setback + nv * mount_hole_inset; b2 = b - u * setback + nv * mount_hole_inset; L2 = norm(b2 - a2); n = (e_max_spc > 0) ? max(1, ceil(L2 / e_max_spc)) : 1; if (L2 > mount_hole_d) { if (do_holes) for (k = [0 : n]) translate(a2 + (b2 - a2) * k / n) circle(d = mount_hole_d); if (do_slits) { lmax = min(edge_slit_length, L2/n - mount_hole_d - 6); if (lmax > 4) for (k = [0 : n-1]) translate(a2 + (b2 - a2) * (k + 0.5) / n) rotate(atan2(u[1], u[0])) rounded_rect(lmax, edge_slit_width, edge_slit_width/2); } } } } // ---------- lightening holes ---------- module lightening_hole() let (ls = min(lightening_size, v_bar - 3)) // keep >=1.5mm web above/below if (ls > 2) { if (lightening_style == "hex") hexagon(ls); else circle(d = ls); } module lightening_set_rect() for (j = [0 : n_rows-2], i = [0 : row_cols(j)-1]) translate([col_x(i, j), row_y(j) + e_v_pitch/2]) lightening_hole(); module lightening_set_quad() for (j = [0 : qn_rows-2], i = [0 : qn_cols-1]) { x = qcol_x(i) + ((e_stagger && j%2==1) ? e_h_pitch/2 : 0); y = qrow_y(j); if (slot_fits(x, y) && slot_fits(x, y + e_v_pitch)) translate([x, y + e_v_pitch/2]) lightening_hole(); } // ---------- outlines ---------- module outline_rect() if (e_corner_sty == "chamfer") chamfered_rect(p_w, p_h, e_corner_r); else rounded_rect(p_w, p_h, e_corner_r); module outline_quad() if (e_corner_r <= 0) polygon(q_pts); else if (e_corner_sty == "chamfer") offset(delta = e_corner_r, chamfer = true) offset(delta = -e_corner_r) polygon(q_pts); else offset(r = e_corner_r) offset(delta = -e_corner_r) polygon(q_pts); // ---------- panel ---------- module panel_2d() { difference() { if (e_shape == "quad") outline_quad(); else outline_rect(); if (e_shape == "quad") slot_grid_quad(); else slot_grid_rect(); if (e_mount) { if (e_shape == "quad") quad_perimeter(true, false); else mount_hole_set_rect(); } if (e_edge_slits) { if (e_shape == "quad") quad_perimeter(false, true); else edge_slit_set_rect(); } if (e_lightening) { if (e_shape == "quad") lightening_set_quad(); else lightening_set_rect(); } if (e_inter) { if (e_shape == "quad") inter_slit_set_quad(); else inter_slit_set_rect(); } if (e_cslits && e_corner_sty == "chamfer" && e_shape == "rect") corner_slit_set(); } } module panel_final() if (kerf > 0) offset(r = kerf/2) panel_2d(); else panel_2d(); // ---------- live dimension annotations (preview only, never exported) ---------- module dimension_annotations() { ts = max(8, min(22, max(p_w, p_h) * 0.04)); // text size scales with panel off = ts * 1.4; // distance from panel edge lw = ts * 0.08; // dimension line weight color("red") { // overall width - above the panel translate([0, p_h/2 + off]) { square([p_w, lw], center=true); for (x = [-p_w/2, p_w/2]) translate([x, 0]) square([lw, ts*0.7], center=true); translate([0, ts*0.35]) text(str(round(p_w*10)/10, " mm / ", fmt_in(p_w), "\""), size=ts, halign="center", valign="baseline"); } // overall height - right of the panel translate([p_w/2 + off, 0]) { square([lw, p_h], center=true); for (y = [-p_h/2, p_h/2]) translate([0, y]) square([ts*0.7, lw], center=true); translate([ts*1.15, 0]) rotate(90) text(str(round(p_h*10)/10, " mm / ", fmt_in(p_h), "\""), size=ts, halign="center", valign="baseline"); } // slot count + weight - below the panel translate([0, -p_h/2 - off]) text(str(n_slots_total, " slots", material == "none" ? "" : str(" | ", weight_str)), size=ts*0.9, halign="center", valign="top"); // advisory warnings - below that if (len(warn_msgs) > 0) for (i = [0 : len(warn_msgs)-1]) translate([0, -p_h/2 - off - (i+1)*ts*1.6]) text(str("! ", warn_msgs[i]), size=ts*0.85, halign="center", valign="top"); } } // ---------- nesting: tile several panels into one cut job ---------- nx_ = max(1, nest_x); ny_ = max(1, nest_y); sheet_w = nx_ * (p_w + kerf) + (nx_ - 1) * nest_gap; sheet_h = ny_ * (p_h + kerf) + (ny_ - 1) * nest_gap; if (nx_ * ny_ > 1) echo(str("=== nested ", nx_, " x ", ny_, " = ", nx_*ny_, " panels, sheet ", sheet_w, " x ", sheet_h, " mm (", fmt_in(sheet_w), " x ", fmt_in(sheet_h), " in) ===")); // ---------- engrave layer ---------- module engrave_2d() if (engrave_text != "") translate([engrave_text_x, engrave_text_y]) text(engrave_text, size = engrave_text_size, halign = "center", valign = "center"); assert(output_layer != "engrave" || engrave_text != "", "output_layer=engrave but engrave_text is empty - nothing to export"); module nest_positions() for (i = [0 : nx_-1], j = [0 : ny_-1]) translate([i * (p_w + kerf + nest_gap), j * (p_h + kerf + nest_gap)]) children(); module nested() nest_positions() panel_final(); module nested_engrave() nest_positions() engrave_2d(); if (output_layer == "engrave") { // engrave layer only - same panel positions as the cut layer, // so both SVGs import into XCS aligned at 0,0 if (preview_3d) linear_extrude(0.5) nested_engrave(); else nested_engrave(); } else if (preview_3d) { linear_extrude(material_thickness) nested(); if ($preview) { color("blue") translate([0, 0, material_thickness]) linear_extrude(0.3) nested_engrave(); if (show_dimensions) linear_extrude(0.5) dimension_annotations(); } } else { nested(); // $preview is false during any export/render, so neither the blue // engrave-position guide nor the dimensions can reach the cut SVG if ($preview) { color("blue") nested_engrave(); if (show_dimensions) dimension_annotations(); } }