// When a small distance is needed to overlap shapes for boolean cutting, etc. epsilon = 0.01; module bevel(l, w, h){ polyhedron( points=[[0,0,0], [l,0,0], [l,w,0], [0,w,0], [0,0,h], [l,0,h]], faces=[[0,1,2,3],[5,4,3,2],[0,4,5,1],[0,3,4],[5,2,1]] ); } module shim(l, w, h){ polyhedron( points=[[-l/2,-w/2,0], [l/2,-w/2,0], [l/2,w/2,0], [-l/2,w/2,0], [-l/2+w/4,0,h], [l/2-w/4,0,h]], faces=[[0,1,2,3],[5,4,3,2],[0,4,5,1],[0,3,4],[5,2,1]] ); } module halfBevel(l, w, h) { bevel(l,h,h); translate([0,w,0]) rotate(a = 270) bevel(w,h,h); } module fullBevel(l, w, h, b) { halfBevel(l, w, b); translate([l,w,0]) rotate(a = 180) halfBevel(l, w, 1); translate([0,0,h]) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([l,0,h]) rotate(a = 90) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([l,w,h]) rotate(a = 180) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([0,w,h]) rotate(a = 270) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); } module tubeBevel(l, w, h, b) { translate([0,0,h]) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([l,0,h]) rotate(a = 90) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([l,w,h]) rotate(a = 180) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); translate([0,w,h]) rotate(a = 270) rotate(a = 90, v = [0, 1, 0]) bevel(h,b,b); } module beveledCube(l, w, h, b) { difference() { cube([l,w,h]); translate([-epsilon, -epsilon, -epsilon]) fullBevel(l + 2 * epsilon, w + 2 * epsilon, h + 2 * epsilon, 1); } } module squareTube(l, w, h, t) { difference() { cube([l,w,h]); translate([t,t,-epsilon]) cube([l - 2 * t, w - 2 * t, h + 2 * epsilon]); } } module beveledTube(l, w, h, t, b) { difference() { squareTube(l, w, h, 2); translate([-epsilon,-epsilon,epsilon]) tubeBevel(l + 2 * epsilon, w + 2 * epsilon, h + epsilon, b); } translate([t,t,0]) tubeBevel(l - 2 * t, w - 2 * t, h, b); } module endCap(cl, cw, ch, tl, tw, th, sl, sw, sh, t, b) { translate([ (cl - tl) / 2, (cw - tw) / 2, 0]) beveledTube(tl, tw, th, t, b); translate([ 0, 0, -ch ]) beveledCube(cl, cw, ch, b); translate([ cl / 2, (cw - tw) / 2, th / 2 ]) rotate(a = 90, v = [1, 0, 0]) shim(sl, sw, sh); translate([ cl / 2, cw / 2 + tw / 2, th / 2 ]) rotate(a = 270, v = [1, 0, 0]) shim(sl, sw, sh); } endCap(50, 30, 4, 46.5, 27.14, 13, 4, 2, 0.5, 2, 1);