118 lines
4.3 KiB
OpenSCAD
118 lines
4.3 KiB
OpenSCAD
// Face-Down Oval Zipper Pull Template
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// Designed for face-down printing: text and border are channels in blue layer (printed first),
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// then white backing fills the channels and covers the back.
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// When flipped over, shows white text/border on blue background.
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// Parameters - these can be overridden from command line
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name = "NAME"; // Text to display on zipper pull
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oval_width = 96; // Width of blue oval (mm) - total with border will be 100mm (96 + 2*2)
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oval_height = 30; // Height of blue oval (mm) - total with border will be 34mm (30 + 2*2)
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blue_thickness = 1; // Thickness of blue layer (mm) - this is the "show" side
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white_thickness = 1.5; // Thickness of white backing layer (mm)
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base_text_size = 13; // Base font size for medium names
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// Dynamic font sizing based on name length (mimics Ford oval proportions)
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// "Fred" (4 chars) at 13mm gives ~20% coverage - our target
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name_length = len(name);
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text_size = name_length <= 3 ? 18 : // Short names (Zoe, Sam, Al) - larger (~21% coverage)
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name_length <= 5 ? 13 : // Medium names (Fred, John, Mary) - standard (~20% coverage)
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name_length <= 8 ? 11 : // Longer names (Michael, Jessica) - smaller (~25% coverage)
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11; // Very long names (Christopher) - increased to 11mm (~35% coverage)
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// Border parameters
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border_width = 2; // Width of the white border around the oval (mm)
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// Hole parameters for zipper pull
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hole_diameter = 4; // Diameter of the hole (mm)
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hole_clearance = 4; // Minimum clearance from edge of outer border (mm)
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// Total dimensions
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total_width = oval_width + border_width*2; // 100mm
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total_height = oval_height + border_width*2; // 34mm
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// Hole position - on LEFT side when viewed from show side
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// Since we print face-down, hole appears on RIGHT during printing
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// When flipped, it will be on the left as expected
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hole_x = -(total_width/2) + (hole_diameter/2) + hole_clearance;
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// Module to create an oval (ellipse)
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module oval(width, height, depth) {
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scale([width/2, height/2, 1])
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cylinder(h=depth, r=1, $fn=100);
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}
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// Module for text with fake bold effect
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module bold_text() {
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for (x = [-0.3, 0, 0.3]) {
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for (y = [-0.3, 0, 0.3]) {
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translate([x, y, 0])
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linear_extrude(height=blue_thickness + 0.1)
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text(name,
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size=text_size,
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font="Fordscript",
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halign="center",
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valign="center");
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}
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}
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}
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// Blue layer with channels for text and border (prints first, face-down)
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// The channels will be filled with white when the white layer is printed
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module blue_layer() {
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color("RoyalBlue")
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difference() {
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// Full blue oval
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oval(total_width, total_height, blue_thickness);
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// Cut out the border ring channel (will be filled with white)
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translate([0, 0, -0.05])
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difference() {
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oval(total_width, total_height, blue_thickness + 0.1);
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oval(oval_width, oval_height, blue_thickness + 0.2);
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}
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// Cut out text channels (will be filled with white)
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translate([0, 0, -0.05])
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bold_text();
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// Cut out hole
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translate([hole_x, 0, -0.05])
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cylinder(h=blue_thickness + 0.1, d=hole_diameter, $fn=50);
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}
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}
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// White backing layer (prints second, on top of blue)
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// Also fills the text and border channels
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module white_layer() {
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color("white")
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difference() {
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union() {
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// Main backing layer on top of blue
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translate([0, 0, blue_thickness])
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oval(total_width, total_height, white_thickness);
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// Fill the border channel
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difference() {
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oval(total_width, total_height, blue_thickness);
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oval(oval_width, oval_height, blue_thickness + 0.1);
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}
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// Fill the text channels
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bold_text();
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}
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// Cut out hole through entire white layer
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translate([hole_x, 0, -0.05])
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cylinder(h=blue_thickness + white_thickness + 0.2, d=hole_diameter, $fn=50);
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}
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}
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// Main zipper pull assembly
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module zipper_pull() {
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blue_layer();
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white_layer();
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}
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// Generate the zipper pull
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zipper_pull();
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