add bottletag generation script

.gitignore

@@ -1 +1,2 @@
 stls/
+private

bunnyear_headband.scad

@@ -0,0 +1,20 @@
+use <catear_headband.scad>
+include <headband.scad>
+
+module bunnyear_headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND, ear_scale=0.5, ear_bend_factor=0.2, ear_stretch_factor=8, ear_angle=30) {
+  catear_headband(
+    debug=debug,
+    size=size,
+    height=height,
+    thickness=thickness,
+    part=part,
+    stretch_len=stretch_len,
+    tip_len=tip_len,
+    tip_bend=tip_bend,
+    ear_scale=ear_scale,
+    ear_bend_factor=ear_bend_factor,
+    ear_stretch_factor=ear_stretch_factor,
+    ear_angle=ear_angle);
+}
+
+bunnyear_headband();

c3cat-bottle-clip/c3cat-bottle-clip.scad

@@ -26,6 +26,16 @@
  */
 
 include <write/Write.scad>
+use <catear_headband.scad>
+
+$fn = 360;
+
+NAME = "c3cat";
+LOGO_FILE = ""; // empty string is catear model
+RENDER_COLOR_ONE = true;
+RENDER_COLOR_TWO = true;
+RENDER_COLOR_THREE = true;
+USE_TINY_EARS = true;
 
 /**
  * Creates one instance of a bottle clip name tag. The default values are
@@ -44,62 +54,137 @@ include <write/Write.scad>
  * font: the path to a font for Write.scad.
  */
 
-/* currently openscad fails to render `Ohren_4.stl` outside of the preview mode */
-//difference() {
-  rotate(45, [0, 0, 1]) bottle_clip(name="c3cat");
-//  translate([ 15, 0, 18]) rotate(80, [0, 1, 0]) catear();
-//  translate([-15, 0, 18]) rotate(-80, [0, 1, 0]) catear();
-//}
-//
-//translate([0,  5, 0]) catear();
-//rotate(180) translate([0,  5, 0]) catear();
+/**
+ * currently openscad fails to render the original `Ohren_4.stl` outside of the preview mode
+ * according to [the wiki](https://en.wikibooks.org/wiki/OpenSCAD_User_Manual/FAQ#Why_is_my_imported_STL_file_appearing_with_F5_but_not_F6?) this is the stls fault
+ * using meshlab to run `Filters` -> `Cleaning and Repairing` -> `Remove T-Vertices` by `Edge-Flip` with `Ratio` of `1000000` before importing the stl works but but two errors remain.
+ */
+scale([0.2, 0.2, 0.2]) {
+  difference() {
+    scale([5, 5, 5]) rotate(45, [0, 0, 1]) bottle_clip(name=NAME);
+    translate([ 15*5, 0*5, 18*5]) rotate(80, [0, 1, 0]) catear();
+    translate([-15*5, 0*5, 18*5]) rotate(-80, [0, 1, 0]) catear();
+  }
+  if (RENDER_COLOR_TWO) {
+    color("orange")
+      translate([ 15*5, 0*5, 18*5])
+        rotate(80, [0, 1, 0])
+          catear();
+  }
+  if (RENDER_COLOR_THREE) {
+    color("yellow")
+      translate([-15*5, 0*5, 18*5])
+        rotate(-80, [0, 1, 0])
+          catear();
+  }
+}
+
+module name(name, font, rl, ht, ru) {
+  writecylinder(
+    text=name,
+    where=[0,0,0],
+    radius=rl+0.5,
+    height=ht/13*7,
+    h=ht/13*4,
+    t=max(rl,ru),
+    font=font);
+}
+
+module logo(logo, rl, ht, ru, width) {
+  echo("logo: ", logo);
+  if(logo == "") {
+    ear_size=ht;
+    echo("ht: ", ht);
+    echo("ru: ", ru);
+    echo("rl: ", rl);
+    echo("width: ", width);
+    translate([0,-max(ru,rl),ht*3/4+.5])
+      rotate([90,0,0])
+        scale([1,1,1])
+          scale([ht/100,ht/100,1])
+            translate([0, -ht/2,0])
+              rotate(-90, [0, 0, 1])
+                catear_headband(
+                  size=ear_size,
+                  height=max(ru,rl),
+                  thickness=width,
+                  stretch_len=0,
+                  tip_len=0,
+                  details=false,
+                  with_rake=false
+                );
+  } else {
+        // The logo has been split in 3 parts. // well was... TODO
+/*
+          rotate([0,0,-48]) translate([0,0,ht*3/4-0.1])
+            rotate([90,0,0])
+              scale([0.9,0.9,1])
+                scale([ht/100,ht/100,1])
+                  translate([-25,-29,0.5])
+                    linear_extrude(height=max(ru,rl)*2)
+                      import("logo_1.dxf");
+*/
+          translate([0,0,ht*3/4-0.1])
+            rotate([90,0,0])
+              scale([0.8,0.8,1])
+                scale([ht/100,ht/100,1])
+                  translate([-18,-22,0.5])
+                    linear_extrude(height=max(ru,rl)*2)
+                      import(logo);
+/*
+          rotate([0,0,44]) translate([0,0,ht*3/4-0.1])
+            rotate([90,0,0])
+              scale([0.7,0.7,1])
+                scale([ht/100,ht/100,1])
+                  translate([-25,-26,0.5])
+                    linear_extrude(height=max(ru,rl)*2)
+                      import("logo_3.dxf");
+*/
+  }
+}
 
 module bottle_clip(ru=13, rl=17.5, ht=26, width=2.5, name="c3cat", font="write/orbitron.dxf", logo="") {
-
 	e=100;  // should be big enough, used for the outer boundary of the text/logo
-
-  difference() {
-    rotate([0,0,-45]) union() {
-      // main cylinder
-      cylinder(r1=rl+width, r2=ru+width, h=ht);
-      // text and logo
-      if(logo == "") {
-        color("orange") writecylinder(name, [0,0,0], rl+0.5, ht/13*7, h=ht/13*4, t=max(rl,ru), font=font);
-        translate([4.7, -rl, ht*1.08]) rotate(-10, [1, 0, 0]) rotate(76, [0, 1, 0]) scale([0.08, 2, 0.08]) color("red") import("catears.stl");
-      } else {
-        color("orange") writecylinder(name, [0,0,0], rl+0.5, ht/13*7, h=ht/13*4, t=max(rl,ru), font=font);
-
-        // The logo has been split in 3 parts.
-/*
-        rotate([0,0,-48]) translate([0,0,ht*3/4-0.1])
-          rotate([90,0,0])
-            scale([0.9,0.9,1])
-              scale([ht/100,ht/100,1])
-                translate([-25,-29,0.5])
-                  linear_extrude(height=max(ru,rl)*2)
-                    import("logo_1.dxf");
-*/
-        translate([0,0,ht*3/4-0.1])
-          rotate([90,0,0])
-            scale([0.8,0.8,1])
-              scale([ht/100,ht/100,1])
-                translate([-18,-22,0.5])
-                  linear_extrude(height=max(ru,rl)*2)
-                    import(logo);
-/*
-        rotate([0,0,44]) translate([0,0,ht*3/4-0.1])
-          rotate([90,0,0])
-            scale([0.7,0.7,1])
-              scale([ht/100,ht/100,1])
-                translate([-25,-26,0.5])
-                  linear_extrude(height=max(ru,rl)*2)
-                    import("logo_3.dxf");
-*/
+  rotate([0,0,-45]) {
+    // main cylinder
+    if (RENDER_COLOR_ONE) {
+      color("black") difference() {
+        cylinder(r1=rl+width, r2=ru+width, h=ht);
+        difference() {
+          union() {
+            name(name=name, font=font, rl=rl, ht=ht, ru=ru);
+            logo(logo=logo, rl=rl, ht=ht, ru=ru, width=width);
+          }
+          cylinder(r1=rl+width/2, r2=ru+width/2, h=ht);
+        }
+        translate([0,0,-1])
+          cylinder(r1=rl, r2=ru, h=ht+2);
+        // finally, substract a cube as a gap so we can clip it to the bottle
+        rotate([0, 0, 45])
+          translate([0,0,-1])
+            cube([50,50,50]);
       }
     }
-    // inner cylinder which is substracted
-    translate([0,0,-1])
-      cylinder(r1=rl, r2=ru, h=ht+2);
+    // text
+    if (RENDER_COLOR_TWO) {
+      color("orange") difference() {
+        name(name=name, font=font, rl=rl, ht=ht, ru=ru);
+        cylinder(r1=rl+width/2, r2=ru+width/2, h=ht);
+        outer_cutoff(rl, e, ru, ht, width);
+      }
+    }
+    // logo
+    if (RENDER_COLOR_THREE) {
+      color("yellow") difference() {
+        logo(logo=logo, rl=rl, ht=ht, ru=ru, width=2*width);
+        cylinder(r1=rl+width/2, r2=ru+width/2, h=ht);
+        outer_cutoff(rl, e, ru, ht, width);
+      }
+    }
+  }
+}
+
+module outer_cutoff(rl, e, ru, ht, width) {
     // outer cylinder which is substracted, so the text and the logo end
     // somewhere on the outside ;-)
     difference () {
@@ -109,15 +194,14 @@ module bottle_clip(ru=13, rl=17.5, ht=26, width=2.5, name="c3cat", font="write/o
         // depth is > 0.7
         cylinder(r1=rl+width+0.7, r2=ru+width+0.7, h=ht+2);
     }
-    // finally, substract a cube as a gap so we can clip it to the bottle
-    translate([0,0,-1]) cube([50,50,50]);
-  }
 }
 
 module catear() {
-  rotate(-90, [0, 0, 1]) union() {
-    scale([0.2,  0.2, 0.2]) translate([0, -85]) import("catear.stl");
-    scale([0.2, -0.2, 0.2]) translate([0, -85]) import("catear.stl");
+  if (USE_TINY_EARS) {
+      rotate(-90, [0, 0, 1]) union() {
+      scale([1,  1 ,1]) translate([0, -85]) import("catear.stl");
+      scale([1, -1, 1]) translate([0, -85]) import("catear.stl");
+    }
   }
 }
 

c3cat-bottle-clip/catear_headband.scad

@@ -0,0 +1 @@
+../catear_headband.scad

catear_headband.scad

@@ -0,0 +1,124 @@
+include <globals.scad>;
+
+use <headband.scad>;
+use <chamfer.scad>;
+
+module catear(height, thickness, fractal=0, side_len=30, bend_factor=0.5, stretch_factor=1.2, debug=false, chamfer=CHAMFER, chamfer_shape=CHAMFER_SHAPE, details=true) {
+  $A=[0, side_len/2];
+  $B=[0,-side_len/2];
+  $C=[-(side_len/2/sin(120))*1.5*stretch_factor, 0];
+  $c=sqrt(pow($A.x-$B.x, 2)+pow($A.y-$B.y, 2));
+  $b=sqrt(pow($A.x-$C.x, 2)+pow($A.y-$C.y, 2));
+  $a=sqrt(pow($C.x-$B.x, 2)+pow($C.y-$B.y, 2));
+  $hc=-$C.x;
+  $alpha=asin($hc/$b);
+  $beta=$alpha;
+  $gamma=180-$alpha-$beta;
+  $delta=180*bend_factor;
+  $bend_radius=$a/(2*cos(90-$delta/2));
+  $bend_offset=$bend_radius*sin(90-$delta/2);
+
+  translate([0, -$c/2, 0])
+    rotate($beta, [0, 0, 1])
+      translate([0, $a/2, 0])
+        translate([$bend_offset, 0, 0])
+          color("#00ffff")
+            chamfer(size=(details)?chamfer:0, child_h=height, child_bot=-height/2, shape=chamfer_shape)
+              partial_ring(
+                part=$delta/360,
+                radius=$bend_radius,
+                thickness=thickness,
+                height=height
+              );
+  translate([0, $c/2, 0])
+    rotate(-$alpha, [0, 0, 1])
+      translate([0, -$b/2, 0])
+        translate([$bend_offset, 0, 0])
+          color("#ff00ff")
+            chamfer(size=(details)?chamfer:0, child_h=height, child_bot=-height/2, shape=chamfer_shape)
+              partial_ring(
+                part=$delta/360,
+                radius=$bend_radius,
+                thickness=thickness,
+                height=height
+              );
+  translate($A) color("#aaaaaa")
+    chamfer(size=chamfer, child_h=height, child_bot=-height/2, shape=chamfer_shape)
+      cylinder(h=height, d=thickness, center=true);
+  translate($B) color("#bbbbbb")
+    chamfer(size=chamfer, child_h=height, child_bot=-height/2, shape=chamfer_shape)
+      cylinder(h=height, d=thickness, center=true);
+  translate($C) color("#cccccc")
+    chamfer(size=chamfer, child_h=height, child_bot=-height/2, shape=chamfer_shape)
+      cylinder(h=height, d=thickness, center=true);
+
+  if (debug) {
+    echo("A", $A, "a", $a, "alpha", $alpha);
+    echo("B", $B, "b", $b, "beta ", $beta);
+    echo("C", $C, "c", $c, "gamma", $gamma);
+    echo("bend_factor", bend_factor);
+    echo("delta:", $delta);
+    echo("bend_radius", $bend_radius);
+    echo("bend_offset", $bend_offset);
+    color("#000000") cylinder(h=4, d=4);
+    translate($C/2) color("red") cube([$hc, thickness, height*1.1], center=true);
+    color("red") cube([thickness, $c, height*1.1], center=true);
+    color("red") translate([0, $c/2, 0])
+      rotate(-$alpha, [0, 0, 1])
+        translate([0, -$b/2, 0])
+          cube([thickness,$b, height*1.1], center=true);
+    color("red") translate([0, -$c/2, 0])
+      rotate($beta, [0, 0, 1])
+        translate([0, $a/2, 0])
+          cube([thickness, $a, height*1.1], center=true);
+  }
+}
+
+module catear_headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND, ear_scale=1.5, ear_bend_factor=0.15, ear_stretch_factor=1.2, ear_angle=42, chamfer=CHAMFER, chamfer_shape=CHAMFER_SHAPE, with_rake=true, details=true) {
+
+  $a=size/2*ear_scale;
+  $delta=2*(acos($a/(size*2))-90);
+  ear_offset=size*sin(90-$delta/2);
+
+  union() {
+    rotate( ear_angle, [0, 0, 1]) {
+      translate([-ear_offset, 0, 0]) catear(
+        debug=debug,
+        height=height,
+        thickness=thickness,
+        side_len=size/2*ear_scale,
+        bend_factor=ear_bend_factor,
+        stretch_factor=ear_stretch_factor,
+        chamfer=chamfer,
+        chamfer_shape=chamfer_shape,
+        details=details
+      );
+    }
+    rotate(-ear_angle, [0, 0, 1]) {
+      translate([-ear_offset, 0, 0]) catear(
+        debug=false,
+        height=height,
+        thickness=thickness,
+        side_len=size/2*ear_scale,
+        bend_factor=ear_bend_factor,
+        stretch_factor=ear_stretch_factor,
+        chamfer=chamfer,
+        chamfer_shape=chamfer_shape,
+        details=details
+      );
+    }
+    headband(
+      size=size,
+      height=height,
+      thickness=thickness,
+      part=part,
+      stretch_len=stretch_len,
+      tip_len=tip_len,
+      tip_bend=tip_bend,
+      with_rake=with_rake,
+      details=details
+    );
+  };
+}
+
+catear_headband();

catear_pedestal.scad

@@ -0,0 +1,49 @@
+include <globals.scad>
+
+use <catear_headband.scad>
+
+SCALE_FACTOR=SIZE/9;
+
+echo("scale factor: ", SCALE_FACTOR);
+echo("bottom diameter: ", SIZE/SCALE_FACTOR);
+
+
+difference() {
+  union()
+    for (i=[-1,1])
+      translate([i*2, 0, 0])
+        rotate(i*90, [0, 1, 0])
+          scale(1/SCALE_FACTOR)
+            union() {
+              translate([0, 0, SIZE+20+60])
+                rotate(90, [0, 1, 0])
+                  scale(1.6)
+                    catear_headband(thickness=5, with_rake=false);
+              translate([0, 0, 20])
+                cylinder(h=10, r=SIZE, $fn=360);
+              cylinder(h=20, d=SIZE, $fn=360);
+            }
+  translate([0, 0, -SIZE*(1/SCALE_FACTOR)*5])
+    cube(SIZE*10*(1/SCALE_FACTOR), center=true);
+}
+
+/*
+scale(1/SCALE_FACTOR) {
+translate([0, 0, 30])
+scale([1, 1, -1])
+difference() {
+  union() {
+    translate([0, 0, 20])
+      cylinder(h=10, r=SIZE, $fn=360);
+    cylinder(h=20, d=SIZE, $fn=360);
+  }
+  translate([0, 0, SIZE+20+60])
+    rotate(90, [0, 1, 0])
+      scale(1.6)
+        catear_headband(thickness=5, with_rake=false);
+}
+scale(1.6)
+  translate([0, 0, HEIGHT/2])
+    catear_headband(thickness=5, with_rake=false);
+}
+*/

chamfer.scad

@@ -0,0 +1,78 @@
+/// Chamfering OpenSCAD Example
+/// Written by Robert Quattlebaum, 2022-12-14
+///
+/// This example shows a method for adding a chamfer to a certain
+/// class of 3D objects where the profile in the Z dimension doesn't
+/// change significantly.
+///
+/// You must specify the size of the chamfer, the height of the child
+/// and the Z-offset for the bottom of the object. You can also specify
+/// the shape of the chamfer, which can be either "cone", "curve", "curve-in",
+/// or "pyramid".
+///
+/// This process is ultimately slow, but should be faster than using minkowski.
+
+module chamfer(size=2, child_h=5, child_bot=0, shape="curve") {
+    chamfer_size=size;
+    
+    module chamfer_shape() {
+		if (shape == "cone") {
+            $fn=16;
+            cylinder(chamfer_size/2,chamfer_size/2,0);
+        } else if (shape == "curve") {
+            $fn=4;
+            for( y = [0:1/$fn:1]) {
+                cylinder(chamfer_size/2*(1-y),chamfer_size/2/cos(180/$fn)*y,0);
+            }
+        } else if (shape == "curve-in") {
+            $fn=16;
+            intersection() {
+                sphere(chamfer_size/2/cos(180/$fn));
+                translate([0,0,chamfer_size/2])
+                    cube(chamfer_size, center=true);
+            }
+        } else if (shape == "pyramid") {
+            $fn=4;
+            cylinder(chamfer_size/2/cos(180/$fn),chamfer_size/2,0);
+        }
+    }
+    
+    module lower_chamfer() {
+        minkowski()
+        {
+            linear_extrude(0.0001) difference() {
+                square([1000,1000],center=true);
+                projection()children(0);
+            }
+            chamfer_shape();
+        }
+    }
+
+    module upper_chamfer() {
+		scale([1,1,-1])lower_chamfer()children();
+    }
+    
+    render()difference() {
+        children();
+        translate([0,0,child_bot])lower_chamfer()children();
+        translate([0,0,child_bot+child_h])upper_chamfer()children();
+    }
+}
+
+/////////////////////////////////////////////////////////////////////////
+
+module my_shape(h=5) {
+    translate([0,0,h/2]) {
+        difference() {
+            cube([50,50,h],center=true);
+            cube([20,20,h+1],center=true);
+        }
+        translate([20,21,0])cylinder(h=h,r=20,center=true);
+    }
+}
+
+
+h=5;
+
+chamfer(3, child_h=h, shape="cone")
+    my_shape(h);

foxear_headband.scad

@@ -0,0 +1,20 @@
+use <catear_headband.scad>
+include <headband.scad>
+
+module foxear_headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND, ear_scale=1.2, ear_bend_factor=0.05, ear_stretch_factor=1.2, ear_angle=30) {
+  catear_headband(
+    debug=debug,
+    size=size,
+    height=height,
+    thickness=thickness,
+    part=part,
+    stretch_len=stretch_len,
+    tip_len=tip_len,
+    tip_bend=tip_bend,
+    ear_scale=ear_scale,
+    ear_bend_factor=ear_bend_factor,
+    ear_stretch_factor=ear_stretch_factor,
+    ear_angle=ear_angle);
+}
+
+foxear_headband();

generate_bottle_tag.sh

@@ -0,0 +1,57 @@
+#!/bin/sh
+
+# usage: generate_bottle_tag.sh NAME
+
+set -u
+
+VERSION=2.2
+LOGO_FILE='""'
+TINY_EARS=false
+FN=90
+
+NAME="\"$1\""
+
+# usage: render NAME PART
+render() {
+	case "$2" in
+		body)
+			ONE=true
+			TWO=false
+			THREE=false
+			;;
+		name)
+			ONE=false
+			TWO=true
+			THREE=false
+			;;
+		logo)
+			ONE=false
+			TWO=false
+			THREE=true
+			;;
+		*)
+			echo 'fatal: invalid part' >&2
+			exit 1
+			;;
+	esac
+
+	echo rendering "$1" "$2"
+	openscad \
+		-D "\$fn=${FN}" \
+		-D "USE_TINY_EARS=${TINY_EARS}" \
+		-D "LOGO_FILE=${LOGO_FILE}" \
+		-D "NAME=${NAME}" \
+		-D "RENDER_COLOR_ONE=${ONE}" \
+		-D "RENDER_COLOR_TWO=${TWO}" \
+		-D "RENDER_COLOR_THREE=${THREE}" \
+		-o "stls/c3cat-bottle-clip-v${VERSION}_${NAME}_${PART}.stl" \
+		c3cat-bottle-clip/c3cat-bottle-clip.scad
+}
+
+cd "$(dirname $0)"
+
+for PART in body logo name
+do
+	render "$NAME" "$PART"
+	sleep 1
+done

globals.scad

@@ -0,0 +1,19 @@
+$fn=90;
+DEBUG=false;
+SIZE=60;
+HEIGHT=4.6;
+THICKNESS=3;
+PART=0.7;
+STRETCH_LEN=40;
+TIP_LEN=0.05;
+TIP_BEND=20;
+RAKE_DEPTH=1;
+RAKE_WIDTH=1;
+RAKE_STRETCH=1;
+RAKE_CHAMFER=0.5;
+CHAMFER=1;
+CHAMFER_SHAPE="curve";
+
+INSERTICLE_X = 4.6;
+INSERTICLE_Y = 7.4;
+INSERTICLE_Z = 5.4;

headband.scad

@@ -0,0 +1,59 @@
+include <globals.scad>
+use <chamfer.scad>
+
+module partial_ring(part, radius, thickness, height) {
+  rotate(180-180*part, [0, 0, 1])
+    rotate_extrude(angle=360*part)
+      translate([radius, 0])
+        square([thickness, height], center=true);
+}
+
+module headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND, rake_depth=RAKE_DEPTH, rake_width=RAKE_WIDTH, rake_stretch=RAKE_STRETCH, rake_chamfer=RAKE_CHAMFER, chamfer=CHAMFER, chamfer_shape=CHAMFER_SHAPE, with_rake=true, details=true) {
+  union() {
+    chamfer(size=(details)?chamfer:0, child_h=height, child_bot=-height/2, shape=chamfer_shape) union() {
+      color("purple")
+        partial_ring(part, radius=size, thickness=thickness, height=height);
+      rotate( 90-180*part, [0, 0, 1])
+        translate([stretch_len/2,  size, 0]) {
+          color("orange") cube([stretch_len, thickness, height], center=true);
+            color("purple") translate([stretch_len/2, tip_bend, 0])
+              rotate(90+180*tip_len, [0, 0, 1])
+                partial_ring(
+                  part=tip_len,
+                  radius=tip_bend,
+                  thickness=thickness,
+                  height=height
+                );
+        }
+      rotate(-90+180*part, [0, 0, 1])
+        translate([stretch_len/2, -size, 0]) {
+          color("orange")
+            cube([stretch_len, thickness, height], center=true);
+          color("purple")
+            scale([1, -1, 1])
+              translate([stretch_len/2, tip_bend, 0])
+                rotate(90+180*tip_len, [0, 0, 1])
+                  partial_ring(
+                    part=tip_len,
+                    radius=tip_bend,
+                    thickness=thickness,
+                    height=height
+                  );
+        }
+    }
+    if (with_rake) for (i=[-size/2:size/2]) {
+      rotate(i*2-rake_width/2, [0, 0, 1])
+        intersection() {
+          scale([1, 1, rake_stretch/(rake_depth/height)])
+            translate([0, rake_width/2, 0])
+              rotate_extrude(angle=rake_width)
+                translate([rake_depth/2-size+thickness/2, 0, 0])
+                  scale([1, 0.5, 1])
+                    circle(r=rake_depth, $fn=3);
+          translate([rake_depth/2-size+thickness/2-rake_chamfer, 0, 0])
+            color("red")
+              cube([2*rake_depth, rake_width, height], center=true);
+        }
+    }
+  }
+}

loveboard-cover-r2-cat.scad

@@ -0,0 +1,83 @@
+/**
+ * This requires
+ * https://files.printables.com/media/prints/451501/stls/4205518_58958bba-4c36-4995-b4e7-da5abd1ba821/loveboard-cover-r2.stl
+ * 
+ * to be placed under `./stls/LoveBoard-cover-R2.stl` in order to work
+ * but it needs a run in meshlabs uniform fcae orientation filter for
+ * openscad to be happy with it
+ * 
+ * if rendering is missing the ear infill, `Design` > `Flush Caches`
+ * may be required.
+ */
+ 
+include <headband.scad>
+use <catear_headband.scad>
+
+HEIGHT=11;
+THICKNESS=1;
+SIDE_LEN=20;
+BEND_FACTOR=0.15;
+STRETCH_FACTOR=1.2;
+CHAMFER=0;
+CHAMFER_SHAPE="none";
+DEBUG=false;
+
+FILL=true;
+FILL_HEIGHT_FACTOR=0.9;
+FILL_HEIGHT_FALLOFF_STEP=0;
+FILL_HEIGHT_FALLOFF_FACTOR=0.98;
+FILL_HEIGHT_FALLOFF_EXPONENT_FACTOR=3;
+FILL_STEP=0.5;
+
+module loveboard_cover_r2_cat() {
+  $fn=90;
+  union() {
+    difference() {
+      union() {
+        for (i=[-1,1])
+          scale([i, 1, 1]) 
+            translate([-23, 23, 5.5])
+              rotate(-65) {
+                catear(
+                  height=HEIGHT,
+                  thickness=THICKNESS,
+                  side_len=SIDE_LEN,
+                  bend_factor=BEND_FACTOR,
+                  stretch_factor=STRETCH_FACTOR,
+                  debug=DEBUG,
+                  chamfer=CHAMFER,
+                  chamfer_shape=CHAMFER_SHAPE
+                );
+                if (FILL) {
+                  echo("BEGIN FILL");
+                  for (i=[FILL_STEP:FILL_STEP:(SIDE_LEN-FILL_STEP)])
+                    color([0, (256-i*8)/256,0]) {
+                      fill_height=(
+                        HEIGHT * FILL_HEIGHT_FACTOR
+                      * pow(FILL_HEIGHT_FALLOFF_FACTOR,
+                          (SIDE_LEN-1-i)*FILL_HEIGHT_FALLOFF_EXPONENT_FACTOR)
+                      - ((SIDE_LEN-1-i)*FILL_HEIGHT_FALLOFF_STEP)
+                      );
+                      echo([i, fill_height]);
+                      translate([0, 0, (fill_height-HEIGHT)/2])
+                      catear(
+                        height=fill_height,
+                        thickness=THICKNESS,
+                        side_len=i,
+                        bend_factor=BEND_FACTOR,
+                        stretch_factor=STRETCH_FACTOR,
+                        chamfer=0,
+                        chamfer_shape=CHAMFER_SHAPE
+                      );
+                    }
+                  echo("END FILL");
+                }
+              }
+      }
+      scale(0.9999) hull() import("stls/LoveBoard-cover-R2.stl");
+    }
+    color("red") import("stls/LoveBoard-cover-R2.stl");
+  }
+}
+
+loveboard_cover_r2_cat();

mouseear_headband.scad

@@ -0,0 +1,20 @@
+use <catear_headband.scad>
+include <headband.scad>
+
+module mouseear_headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND, ear_scale=1, ear_bend_factor=0.65, ear_stretch_factor=1, ear_angle=40) {
+  catear_headband(
+    debug=debug,
+    size=size,
+    height=height,
+    thickness=thickness,
+    part=part,
+    stretch_len=stretch_len,
+    tip_len=tip_len,
+    tip_bend=tip_bend,
+    ear_scale=ear_scale,
+    ear_bend_factor=ear_bend_factor,
+    ear_stretch_factor=ear_stretch_factor,
+    ear_angle=ear_angle);
+}
+
+mouseear_headband();

pressfit_catears.scad

@@ -0,0 +1,32 @@
+include <globals.scad>;
+
+use <catear_headband.scad>;
+use <pressfit_headband.scad>;
+use <chamfer.scad>;
+
+EAR_SCALE = 1.5;
+EAR_BEND_FACTOR = 0.15;
+EAR_STRETCH_FACTOR = 1.2;
+
+difference() {
+translate([20*pow(0.99, SIZE/2*EAR_SCALE-1-THICKNESS), 0, -THICKNESS/2])
+union() for (i=[0:SIZE/2*EAR_SCALE-1]) {
+  j=pow(0.99, i);
+  chamfer_ = floor(abs(2*i/(SIZE/2*EAR_SCALE-1)-1));
+  translate([-j*20, 0, 0])
+    rotate(90, [0, 1, 0])
+      /*chamfer(size=1, child_h=1, child_bot=-0.5, shape=CHAMFER_SHAPE)*/
+        catear(
+          debug=DEBUG,
+          height=INSERTICLE_Z*1.2,
+          thickness=THICKNESS,
+          side_len=SIZE/2*EAR_SCALE-i,
+          bend_factor=EAR_BEND_FACTOR,
+          stretch_factor=EAR_STRETCH_FACTOR,
+          chamfer=chamfer_,
+          chamfer_shape=CHAMFER_SHAPE
+        );
+}
+translate([0, 0, -THICKNESS]) cube([100, 100, THICKNESS], center=true);
+scale([1, 1, 2]) inserticle();
+}

pressfit_headband.scad

@@ -1,126 +1,12 @@
-$fn=360;
+include <globals.scad>
+
+use <headband.scad>
 
 module inserticle() {
-    cube([4.6, 7.4, 5.4], center=true);
+    cube([INSERTICLE_X, INSERTICLE_Y, INSERTICLE_Z], center=true);
 }
 
-module testblock_inserticle() {
-    union() {
-        translate([0, 0, 5.4/2]) inserticle();
-        translate([0, 0, -5]) cube([15, 12, 10], center=true);
-    }
-}
-
-module testblock_recepticle() {
-    rotate(180, [0, 1, 0]) difference() {
-        translate([0, 0, 5]) cube([15, 12, 10], center=true);
-        translate([0, 0, 5.4/2]) inserticle();
-    }
-}
-
-module catear(height, thickness, fractal=0, side_len=30, bend_factor=0.5, stretch_factor=1.2, debug=false) {
-    $A=[0, side_len/2];
-    $B=[0,-side_len/2];
-    $C=[-(side_len/2/sin(120))*1.5*stretch_factor, 0];
-    $c=sqrt(pow($A.x-$B.x, 2)+pow($A.y-$B.y, 2));
-    $b=sqrt(pow($A.x-$C.x, 2)+pow($A.y-$C.y, 2));
-    $a=sqrt(pow($C.x-$B.x, 2)+pow($C.y-$B.y, 2));
-    $hc=-$C.x;
-    $alpha=asin($hc/$b);
-    $beta=$alpha;
-    $gamma=180-$alpha-$beta;
-    $delta=180*bend_factor;
-    $bend_radius=$a/(2*cos(90-$delta/2));
-    $bend_offset=$bend_radius*sin(90-$delta/2);
-
-    translate([0, -$c/2, 0])
-      rotate($beta, [0, 0, 1])
-        translate([0, $a/2, 0])
-          translate([$bend_offset, 0, 0])
-            color("#00ffff") partial_ring(
-              part=$delta/360,
-              radius=$bend_radius,
-              thickness=thickness,
-              height=height
-            );
-    translate([0, $c/2, 0])
-      rotate(-$alpha, [0, 0, 1])
-        translate([0, -$b/2, 0])
-          translate([$bend_offset, 0, 0])
-            color("#ff00ff") partial_ring(
-              part=$delta/360,
-              radius=$bend_radius,
-              thickness=thickness,
-              height=height
-            );
-    translate($A) color("#aaaaaa") cylinder(h=height, d=thickness, center=true);
-    translate($B) color("#bbbbbb") cylinder(h=height, d=thickness, center=true);
-    translate($C) color("#cccccc") cylinder(h=height, d=thickness, center=true);
-
-    if (debug) {
-      echo("A", $A, "a", $a, "alpha", $alpha);
-      echo("B", $B, "b", $b, "beta ", $beta);
-      echo("C", $C, "c", $c, "gamma", $gamma);
-      echo("bend_factor", bend_factor);
-      echo("delta:", $delta);
-      echo("bend_radius", $bend_radius);
-      echo("bend_offset", $bend_offset);
-      color("#000000") cylinder(h=4, d=4);
-      translate($C/2) color("red") cube([$hc, thickness, height*1.1], center=true);
-      color("red") cube([thickness, $c, height*1.1], center=true);
-      color("red")translate([0, $c/2, 0]) rotate(-$alpha, [0, 0, 1]) translate([0, -$b/2, 0])  cube([thickness, $b, height*1.1], center=true);
-      color("red")translate([0, -$c/2, 0]) rotate($beta, [0, 0, 1]) translate([0, $a/2, 0])  cube([thickness, $a, height*1.1], center=true);
-    }
-}
-
-module partial_ring(part, radius, thickness, height) {
-    rotate(180-180*part, [0, 0, 1])
-        rotate_extrude(angle=360*part)
-            translate([radius, 0])
-                square([thickness, height], center=true);
-}
-
-module headband(size=60, height=4.6, thickness=3, part=0.7, stretch_len=40, tip_len=0.1, tip_bend=20, rake_depth=1.5, rake_width=0.5, rake_stretch=2) {
-    union() {
-        color("purple") partial_ring(part, radius=size, thickness=thickness, height=height);
-        rotate( 90-180*part, [0, 0, 1]) translate([stretch_len/2,  size, 0]) {
-            color("orange") cube([stretch_len, thickness, height], center=true);
-            color("purple") translate([stretch_len/2, tip_bend, 0])
-                rotate(90+180*tip_len, [0, 0, 1])
-                    partial_ring(
-                        part=tip_len,
-                        radius=tip_bend,
-                        thickness=thickness,
-                        height=height
-                    );
-        }
-        rotate(-90+180*part, [0, 0, 1]) translate([stretch_len/2, -size, 0]) {
-            color("orange") cube([stretch_len, thickness, height], center=true);
-            color("purple") scale([1, -1, 1]) translate([stretch_len/2, tip_bend, 0])
-                rotate(90+180*tip_len, [0, 0, 1])
-                    partial_ring(
-                        part=tip_len,
-                        radius=tip_bend,
-                        thickness=thickness,
-                        height=height
-                    );
-        }
-        for (i=[-size/2:size/2]) {
-            rotate(i*2-rake_width/2, [0, 0, 1]) intersection() {
-                scale([1, 1, rake_stretch/(rake_depth/height)])
-                    rotate_extrude(angle=rake_width)
-                        translate([rake_depth/2-size+thickness/2, 0, 0])
-                            scale([1, 0.5, 1])
-                                circle(r=rake_depth, $fn=3);
-                translate([rake_depth/2-size+thickness/2, 0, 0])
-                    color("red")
-                        cube([4*rake_depth, 4*rake_depth, height], center=true);
-            }
-        };
-    };
-}
-
-module pressfit_headband(size=60, height=4.6, thickness=3, part=0.7, stretch_len=40, tip_len=0.1, tip_bend=20, rake_depth=1.5, rake_width=0.5, rake_stretch=2) {
+module pressfit_headband(debug=DEBUG, size=SIZE, height=HEIGHT, thickness=THICKNESS, part=PART, stretch_len=STRETCH_LEN, tip_len=TIP_LEN, tip_bend=TIP_BEND) {
     union() {
         color("pink") { $a=48;
             rotate( $a, [0, 0, 1]) {
@@ -139,87 +25,9 @@ module pressfit_headband(size=60, height=4.6, thickness=3, part=0.7, stretch_len
             part=part,
             stretch_len=stretch_len,
             tip_len=tip_len,
-            tip_bend=tip_bend,
-            rake_depth=rake_depth,
-            rake_width=rake_width,
-            rake_stretch=rake_stretch
+            tip_bend=tip_bend
         );
     };
 }
 
-module catear_headband(debug=false, size=60, height=4.6, thickness=3, part=0.7, stretch_len=40, tip_len=0.1, tip_bend=20, rake_depth=0.5, rake_width=0.5, rake_stretch=.5, ear_scale=1, ear_bend_factor=0.15, ear_stretch_factor=1.4, ear_angle=48) {
-  union() {
-    rotate( ear_angle, [0, 0, 1]) {
-      translate([-size, 0, 0]) catear(
-        debug=debug,
-        height=height,
-        thickness=thickness,
-        side_len=size/2*ear_scale,
-        bend_factor=ear_bend_factor,
-        stretch_factor=ear_stretch_factor
-      );
-    }
-    rotate(-ear_angle, [0, 0, 1]) {
-      translate([-size, 0, 0]) catear(
-        debug=false,
-        height=height,
-        thickness=thickness,
-        side_len=size/2*ear_scale,
-        bend_factor=ear_bend_factor,
-        stretch_factor=ear_stretch_factor
-      );
-    }
-    headband(
-      size=size,
-      height=height,
-      thickness=thickness,
-      part=part,
-      stretch_len=stretch_len,
-      tip_len=tip_len,
-      tip_bend=tip_bend,
-      rake_depth=rake_depth,
-      rake_width=rake_width,
-      rake_stretch=rake_stretch
-    );
-  };
-}
-
-module bunnyear_headband(debug=false, size=60, height=4.6, thickness=3, part=0.7, stretch_len=40, tip_len=0.1, tip_bend=20, rake_depth=1, rake_width=0.5, rake_stretch=1, ear_scale=0.5, ear_bend_factor=0.2, ear_stretch_factor=10, ear_angle=30) {
-  catear_headband(
-    debug=debug,
-    size=size,
-    height=height,
-    thickness=thickness,
-    part=part,
-    stretch_len=stretch_len,
-    tip_len=tip_len,
-    tip_bend=tip_bend,
-    rake_depth=rake_depth,
-    rake_width=rake_width,
-    rake_stretch=rake_stretch,
-    ear_scale=ear_scale,
-    ear_bend_factor=ear_bend_factor,
-    ear_stretch_factor=ear_stretch_factor,
-    ear_angle=ear_angle);
-}
-
-module foxear_headband(debug=false, size=60, height=4.6, thickness=3, part=0.7, stretch_len=40, tip_len=0.1, tip_bend=20, rake_depth=1, rake_width=0.5, rake_stretch=1, ear_scale=1.2, ear_bend_factor=0.01, ear_stretch_factor=1.2, ear_angle=30) {
-  catear_headband(
-    debug=debug,
-    size=size,
-    height=height,
-    thickness=thickness,
-    part=part,
-    stretch_len=stretch_len,
-    tip_len=tip_len,
-    tip_bend=tip_bend,
-    rake_depth=rake_depth,
-    rake_width=rake_width,
-    rake_stretch=rake_stretch,
-    ear_scale=ear_scale,
-    ear_bend_factor=ear_bend_factor,
-    ear_stretch_factor=ear_stretch_factor,
-    ear_angle=ear_angle);
-}
-
-foxear_headband();
+pressfit_headband();

pressfit_horns.scad

@@ -0,0 +1,67 @@
+include <globals.scad>;
+
+use <pressfit_headband.scad>;
+
+$fn=360;
+A=30;
+N=4;
+R=45;
+LENGTH=100;
+TWIST=720;
+STEPS=360;
+SLICES=max(TWIST, STEPS, LENGTH);
+SHEIGHT=LENGTH/STEPS;
+BEND_X_FACTOR=0.5;
+BEND_Y_FACTOR=1;
+
+COLORS=[
+"#f00",
+"#f70",
+"#7f0",
+"#0f0",
+"#0f7",
+"#07f",
+"#00f",
+"#70f",
+"#f07"
+];
+
+difference() {
+  union() for (step=[1:STEPS]) {
+    a = A*(1-(step-1)/STEPS);
+    b = A*(1-step/STEPS);
+    r = TWIST/STEPS*(step-1);
+    sh_xy = 0;
+    sh_yx = 0;
+    sh_xz = 1/STEPS*step*BEND_X_FACTOR;
+    sh_yz = 1/STEPS*step*BEND_Y_FACTOR;
+    sh_zx = 0;
+    sh_zy = 0;
+    t_x = sh_xz*SHEIGHT*(step-1)*0.5;
+    t_y = sh_yz*SHEIGHT*(step-1)*0.5;
+    t_z = LENGTH/STEPS*(step-1);
+    sc_x = 1;
+    sc_y = 1;
+    sc_z = 1;
+    mm = [
+      [sc_x,  sh_xy, sh_xz, t_x],
+      [sh_yx, sc_y,  sh_yz, t_y],
+      [sh_zx, sh_zy, sc_z,  t_z],
+    ];
+    echo(a, b, b/a, r, mm);
+    multmatrix(mm)
+      color(COLORS[(step-1)%9])
+      linear_extrude(
+        SHEIGHT,
+        center=false,
+        twist=TWIST/STEPS,
+        scale=b/a,
+        slices=SLICES/STEPS
+      ) rotate(R-r)
+        circle(d=a, $fn=N);
+  }
+  translate([0, 0, INSERTICLE_Z/2])
+    inserticle();
+}
+
+echo("twist angle: ", TWIST/STEPS);