Kallax Organization.

kallax-organization/constants.scad

@@ -4,3 +4,8 @@ kallaxDepth = 390;    // Full depth of a Kallax shelf
 shelfHeight = 160;    // Height of a Kallax half-shelf (shelf insert)
 shelfWidth = 320;     // Width of a Kallax half-shelf (shelf insert)
 shelfDepth = kallaxDepth - 20;
+
+// boardThickness = 4.7; // 1/8" plywood
+boardThickness = 7.35;
+feltThickness = 2.5;
+feltWidth = 12;

kallax-organization/quarter-drawer-face.scad

@@ -0,0 +1,118 @@
+include <../lib/chamfered-cube.scad>
+include <../lib/rounded-cube.scad>
+include <./constants.scad>
+
+$fn=128;
+l=shelfWidth/2;
+h=shelfHeight/2;
+
+ep = 0.01;
+
+horizontalBoardWidth = 141.5;
+drawerSideHeight = 53;
+sideOffset = 2*feltThickness + boardThickness;
+
+module faceBlank() {
+    size = [shelfWidth/2, shelfHeight/2, 8];
+    chamfer = 4;
+  difference() {
+    roundedCube([l, h, 8], [1, 1, 1]);
+
+    // front face chamfers
+    for (i = [1,3]) {
+      // X-axis
+      translate([-ep, size[1] * floor(i/2), size[2] * (i%2) - chamfer])
+      rotate([45, 0, 0]) cube([size[0] + 2*ep, 1.414*chamfer, 1.414*chamfer]);
+
+      // Y-axis
+      translate([size[0] * floor(i/2) - chamfer, -ep, size[2] * (i%2)])
+      rotate([0, 45, 0]) cube([1.414*chamfer, size[1] + 2*ep, 1.414*chamfer]);
+    }
+
+    // nameplate cutouts
+    translate([(shelfWidth/2 - 76.4)/2, 30, 7]) cube([76.4, 36, 1 + ep]);
+    translate([(shelfWidth/2 - 76.4)/2, 30 + 36, 7])
+    rotate([30, 0, 0]) cube([76.4, 4, 4]);
+
+    // screw holes
+    for (i = [-1, 1]) {
+      color("red")
+      translate([shelfWidth/4 + i*20, 16, -ep]) cylinder(d=3.4, h=8 + 2*ep);
+      translate([shelfWidth/4 + i*20, 16, -ep]) cylinder(d=6.2, h=3 + ep);
+      translate([shelfWidth/4 + i*20, 16, 3 - ep]) cylinder(d1=6.2, d2=3.4, h=1 + 2*ep);
+    }
+
+  }
+
+}
+
+module handle() {
+  handleLen = 64;
+  //difference() {
+  chamferedCube([handleLen, 12, 12], chamfer=3);
+
+  // screw holes
+  for (i = [-1, 1]) {
+    difference() {
+      translate([handleLen/2 + i*20, 6, 12-ep]) cylinder(d=6, h=8 + ep);
+      translate([handleLen/2 + i*20, 6, 12-ep]) cylinder(d=3, h=8 + 2*ep);
+    }
+  }
+}
+
+module lowerRight() {
+  difference() {
+    faceBlank();
+
+    // label
+    color("blue")
+    translate([shelfWidth/4 + 6, shelfHeight/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "LR");
+
+    // horizontal board recess
+    translate([sideOffset, sideOffset, -ep])
+      cube([horizontalBoardWidth, boardThickness, 4+ep]);
+
+    // vertical board recesses
+    translate([sideOffset, sideOffset + boardThickness, -ep])
+      cube([boardThickness, 62, 4+ep]);
+    translate([sideOffset + horizontalBoardWidth - boardThickness, sideOffset + boardThickness, -ep])
+      cube([boardThickness, 62, 4+ep]);
+  }
+}
+
+module lowerLeft() {
+  difference() {
+    faceBlank();
+
+    // label
+    color("blue")
+    translate([shelfWidth/4 + 6, shelfHeight/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "LL");
+  }
+}
+
+module upperRight() {
+  difference() {
+    faceBlank();
+
+    // label
+    color("blue")
+    translate([shelfWidth/4 + 6, shelfHeight/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "UR");
+  }
+}
+
+module upperLeft() {
+  difference() {
+    faceBlank();
+
+    // label
+    color("blue")
+    translate([shelfWidth/4 + 6, shelfHeight/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "UL");
+  }
+}
+
+lowerRight();
+translate([0, 200, 0]) handle();

kallax-organization/quarter-drawer-structural-clips.scad

@@ -1,91 +0,0 @@
-include <./constants.scad>
-
-// all measurements in mm
-boardThickness = 4.7; // 1/8" plywood
-feltThickness = 2.5;
-clipThickness = boardThickness + 2*feltThickness;
-
-// measurements for the wooden panels to cut:
-//
-// ─────────────  - top board (A)
-// │     │     │
-// │───────────│
-// │     │     │
-// │───────────│
-//
-//
-// top board:     320.0 x 370.0
-// bottom board:  305.6 x 370.0  (320 - 2*4.7 - 2*2.5) x 370
-// side boards:   152.8 x 370.0  (160 - 4.7 - 2.5) x 370
-// inner boards:  70.45 x 370.0  ((160 - 3*4.7 - 2*2.5)/2) x 370
-//
-
-module customSupport() {
-  // 45-degree supports
-  difference() {
-    translate([clipThickness/2, -clipThickness/2, 0])
-    cube([1, clipThickness, clipThickness - 2]);
-
-    rotate([45, 0, 0])
-    translate([0, -0.1, -0.1])
-    cube([clipThickness, clipThickness, clipThickness]);
-  }
-}
-
-module cornerClip() {
-  difference() {
-    cube([clipThickness, clipThickness, clipThickness]);
-
-    translate([feltThickness, feltThickness, feltThickness])
-    cube([boardThickness, clipThickness, clipThickness]);
-
-    translate([feltThickness, feltThickness, feltThickness])
-    cube([clipThickness, boardThickness, clipThickness]);
-  }
-}
-
-module sideClip() {
-  difference() {
-    cube([clipThickness, 2 * clipThickness, clipThickness]);
-
-    translate([-0.1, feltThickness, feltThickness])
-    cube([clipThickness + 0.2, boardThickness, clipThickness]);
-
-    translate([feltThickness, feltThickness, feltThickness])
-    cube([boardThickness, 2 * clipThickness, clipThickness]);
-  }
-}
-
-module crossClip() {
-  difference() {
-    cube([2 * clipThickness, clipThickness, clipThickness]);
-
-    translate([-0.1, feltThickness, feltThickness])
-    cube([2 * clipThickness + 0.2, boardThickness, clipThickness]);
-
-    translate([clipThickness - boardThickness/2, -0.1, feltThickness])
-    cube([boardThickness, clipThickness + 0.2, clipThickness]);
-  }
-}
-
-difference() {
-  translate([0, 0, -1.4])
-  union() {
-    for (i = [0:7])
-      translate([i * (clipThickness + 2), clipThickness, 0])
-      rotate([45, 0, 0])
-      cornerClip();
-
-    for (i = [0:7])
-      translate([i * (clipThickness + 2), 3 * clipThickness, 0])
-      rotate([0, 0, 0])
-      sideClip();
-
-    for (i = [0:1])
-      translate([i * (2 * clipThickness + 2), 5 * clipThickness, 0])
-      rotate([45, 0, 0])
-      crossClip();
-  }
-
-  translate([-1, -1, -1.4]) cube([100, 100, 1.4]);
-}

kallax-organization/quarter-drawers.scad

@@ -1,15 +1,16 @@
 include <./constants.scad>
 include <../lib/metric-machine-screws.scad>
+include <../lib/chamfered-cube.scad>
+include <../lib/rounded-cube.scad>
 
 // all measurements in mm
-// boardThickness = 4.7; // 1/8" plywood
+$fn=128;
-boardThickness = 7.35;
+ep = 0.01;
-feltThickness = 2.5;
-feltWidth = 12;
 clipThickness = boardThickness + 2*feltThickness;
 clipWallThickness = 4;
 clipFlangeLength = 24;
 clipFlangeWidth = 16;
+drawerSideOffset = 2*feltThickness + boardThickness;
 
 // measurements for the wooden panels to cut:
 //
@@ -26,6 +27,9 @@ clipFlangeWidth = 16;
 // inner boards:  70.45 x 370.0  ((160 - 3*4.7 - 2*2.5)/2) x 370
 //
 
+function drawerWidth(boxDims) = (boxDims[0] - 3*boardThickness - 4*feltThickness)/2 + 2;
+function drawerHeight(boxDims) = (boxDims[2] - 3*boardThickness - 4*feltThickness)/2;
+
 module fastenerBlank() {
   translate([0, 0.1 + 2 * clipWallThickness + boardThickness, 0])
   rotate([90, 0, 0])
@@ -266,15 +270,198 @@ module bottomPanel(boxDims) {
   }
 }
 
-// TODO
+module drawerFacePlateBlank(boxDims) {
-module drawerFacePlate(outerBoxDims, includeClips = false) {
+  size = [boxDims[0]/2 - 1, boxDims[2]/2 - 1, 8];
+  chamfer = 4;
 
+  difference() {
+    roundedCube(size, [1, 1, 1]);
+
+    // front face chamfers
+    for (i = [1,3]) {
+      // X-axis
+      translate([-ep, size[1] * floor(i/2), size[2] * (i%2) - chamfer])
+      rotate([45, 0, 0]) cube([size[0] + 2*ep, 1.414*chamfer, 1.414*chamfer]);
+
+      // Y-axis
+      translate([size[0] * floor(i/2) - chamfer, -ep, size[2] * (i%2)])
+      rotate([0, 45, 0]) cube([1.414*chamfer, size[1] + 2*ep, 1.414*chamfer]);
+    }
+
+    // nameplate cutouts
+    translate([(boxDims[0]/2 - 76)/2, 30, 7]) cube([76, 36, 1 + ep]);
+    translate([(boxDims[0]/2 - 76)/2, 30 + 36, 7])
+    rotate([30, 0, 0]) cube([76, 4, 4]);
+
+    // screw holes
+    for (i = [-1, 1]) {
+      color("red")
+      translate([boxDims[0]/4 + i*20, 16, -ep]) cylinder(d=3.4, h=8+2*ep);
+      translate([boxDims[0]/4 + i*20, 16, -ep]) cylinder(d=6.2, h=3+ep);
+      //translate([boxDims[0]/4 + i*20, 16, 3 - ep]) cylinder(d1=6.2, d2=3.4, h=1+2*ep);
+    }
+
+  }
 }
 
-module drawerBottom(outerBoxDims, includeClips = false) {
+module lowerLeftDrawerFace(outerDims, boxDims) {
+  rotate([90, 0, 0])
+  difference() {
+    drawerFacePlateBlank(outerDims);
+
+    // label
+    color("blue")
+    translate([outerDims[0]/4 + 6, outerDims[2]/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "LL");
+
+    // horizontal board recess
+    translate([drawerSideOffset, drawerSideOffset, -ep])
+      cube([drawerWidth(boxDims), boardThickness, 4+ep]);
+
+    // vertical board recesses
+    translate([drawerSideOffset, drawerSideOffset + boardThickness - ep, -ep])
+      cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+    translate([
+        drawerSideOffset + drawerWidth(boxDims) - boardThickness,
+        drawerSideOffset + boardThickness - ep,
+        -ep])
+      cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+
+  }
 }
 
-module drawerSide(outerBoxDims, includeClips = false) {
+module lowerRightDrawerFace(outerDims, boxDims) {
+  rotate([90, 0, 0])
+  difference() {
+    translate([1, 0, 0])
+    drawerFacePlateBlank(outerDims);
+
+    // label
+    color("blue")
+    translate([outerDims[0]/4 + 6, outerDims[2]/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "LR");
+
+    union() {
+      // horizontal board recess
+      translate([feltThickness + boardThickness/2, drawerSideOffset, -ep])
+        cube([drawerWidth(boxDims), boardThickness, 4+ep]);
+
+      // vertical board recesses
+      translate([feltThickness + boardThickness/2, drawerSideOffset + boardThickness - ep, -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+      translate([
+          feltThickness + boardThickness/2 + drawerWidth(boxDims) - boardThickness,
+          feltThickness + boardThickness/2 + boardThickness - ep,
+          -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+
+    }
+
+    // translate([-1, -1, 4-ep]) cube([outerDims[0], outerDims[2], 5]);
+  }
+}
+
+module upperRightDrawerFace(outerDims, boxDims) {
+  rotate([90, 0, 0])
+  difference() {
+    translate([1, 0, 0])
+    drawerFacePlateBlank(outerDims);
+
+    // label
+    color("blue")
+    translate([outerDims[0]/4 + 6, outerDims[2]/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "UR");
+
+    union() {
+      // horizontal board recess
+      translate([feltThickness + boardThickness/2, feltThickness + boardThickness/2, -ep])
+        cube([drawerWidth(boxDims), boardThickness, 4+ep]);
+
+      // vertical board recesses
+      translate([
+          feltThickness + boardThickness/2,
+          feltThickness + boardThickness/2 + boardThickness - ep,
+          -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+      translate([
+          feltThickness + boardThickness/2 + drawerWidth(boxDims) - boardThickness,
+          feltThickness + boardThickness/2 + boardThickness - ep,
+          -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+    }
+
+    // translate([-1, -1, 4-ep]) cube([outerDims[0], outerDims[2], 5]);
+  }
+}
+
+module upperLeftDrawerFace(outerDims, boxDims) {
+  rotate([90, 0, 0])
+  difference() {
+    drawerFacePlateBlank(outerDims);
+
+    // label
+    color("blue")
+    translate([boxDims[0]/4 + 6, boxDims[2]/4 - 6, -0.2]) mirror([1, 0, 0])
+    linear_extrude(0.4) text(font="Iosevka", size=6, "UL");
+
+    union() {
+      // horizontal board recess
+      translate([drawerSideOffset, feltThickness + boardThickness/2, -ep])
+        cube([drawerWidth(boxDims), boardThickness, 4+ep]);
+
+      // vertical board recesses
+      translate([
+          drawerSideOffset,
+          feltThickness + boardThickness/2 + boardThickness - ep,
+          -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+      translate([
+          drawerSideOffset + drawerWidth(boxDims) - boardThickness,
+          feltThickness + boardThickness/2 + boardThickness - ep,
+          -ep])
+        cube([boardThickness, drawerHeight(boxDims) - boardThickness + ep, 4+ep]);
+    }
+
+    // translate([-1, -1, 4-ep]) cube([outerDims[0], outerDims[2], 5]);
+  }
+}
+
+
+
+module drawerHandle() {
+  handleLen = 64;
+  //difference() {
+  chamferedCube([handleLen, 12, 12], chamfer=3);
+
+  // screw holes
+  for (i = [-1, 1]) {
+    difference() {
+      translate([handleLen/2 + i*20, 6, 12-ep]) cylinder(d=6, h=8 + ep);
+      translate([handleLen/2 + i*20, 6, 12-ep]) cylinder(d=2.8, h=8 + 2*ep);
+    }
+  }
+}
+
+
+module drawerBottom(boxDims, includeClips = false) {
+  difference() {
+    color ("Tan")
+      cube([
+        drawerWidth(boxDims),
+        boxDims[1], boardThickness]);
+    color("black") translate([10, 10, boardThickness - 1]) linear_extrude(1.1)
+      text(font="Iosevka", size=16, "drawer bottom - plywood");
+  }
+}
+
+module drawerSide(boxDims, includeClips = false) {
+  difference() {
+    color("Wheat")
+      cube([
+        drawerHeight(boxDims) - boardThickness, boxDims[1], boardThickness]);
+    color("black") rotate([0, 0, -90]) translate([-10, 10, boardThickness - 1]) linear_extrude(1.1)
+      text(font="Iosevka", halign = "right", size=16, "drawer side - plywood");
+  }
 }
 
 module assembled(outerBoxDims, includeClips = false) {
@@ -309,6 +496,51 @@ module assembled(outerBoxDims, includeClips = false) {
 
       translate([boardThickness, 0, boardThickness + (innerBoxDims[2] - 3*boardThickness)/2]) bottomPanel(innerBoxDims);
       translate([boardThickness, 0, 0]) bottomPanel(innerBoxDims);
+
+      // drawers
+      translate([boardThickness + feltThickness, 0, boardThickness + feltThickness])
+      for (i = [0:3]) {
+        // felt box
+        color("brown")
+        translate([
+          (i%2)*(innerBoxDims[0]-boardThickness)/2 - feltThickness,
+          0.01,
+          floor(i/2)*(innerBoxDims[2]-boardThickness)/2 - feltThickness])
+        feltClearanceBox([
+          innerBoxDims[0]/2 - 1.5*boardThickness,
+          innerBoxDims[1],
+          innerBoxDims[2]/2 - 1.5*boardThickness]);
+
+        //bottom
+        translate([
+            (i%2)*(innerBoxDims[0]-boardThickness)/2,
+            0,
+            floor(i/2)*(innerBoxDims[2]-boardThickness)/2])
+          drawerBottom(innerBoxDims);
+
+        // side
+        for (j = [0,1]) {
+          translate([
+              boardThickness + (i%2)*(innerBoxDims[0]-boardThickness)/2 +
+                j*(drawerWidth(innerBoxDims) - boardThickness),
+              0,
+              boardThickness + floor(i/2)*(innerBoxDims[2]-boardThickness)/2])
+            rotate([0, -90, 0]) drawerSide(innerBoxDims);
+        }
+      }
+
+      translate([-feltThickness, 0, -feltThickness])
+        lowerLeftDrawerFace(outerBoxDims, innerBoxDims);
+
+      translate([outerBoxDims[0]/2 - feltThickness, 0, -feltThickness])
+        lowerRightDrawerFace(outerBoxDims, innerBoxDims);
+
+      translate([-feltThickness, 0, outerBoxDims[2] / 2 - feltThickness])
+        upperLeftDrawerFace(outerBoxDims, innerBoxDims);
+
+      translate([outerBoxDims[0]/2 - feltThickness, 0, outerBoxDims[2] / 2 - feltThickness])
+        upperRightDrawerFace(outerBoxDims, innerBoxDims);
+
     }
 
     if (includeClips) {
@@ -384,4 +616,17 @@ shelfDims = [shelfWidth, shelfDepth, shelfHeight];
 
 //translate([300, shelfDepth + 40, 0])
 //rotate([0, 0, 90])
-printableSetA();
+//printableSetA();
+
+innerBoxDims =
+  [ shelfDims[0] - 2*feltThickness,
+    shelfDims[1],
+    shelfDims[2] - 2*feltThickness ];
+
+
+//drawerBottom(innerBoxDims);
+//lowerLeftDrawerFace(shelfDims, innerBoxDims);
+//lowerRightDrawerFace(shelfDims, innerBoxDims);
+//upperLeftDrawerFace(shelfDims, innerBoxDims);
+upperRightDrawerFace(shelfDims, innerBoxDims);
+//drawerHandle();