octathingy: many small changes in new capsule array design

Octathingy_common.scad

@@ -173,11 +173,12 @@ holder_ratio = 0.4;
 capsule_cable_diam = 1.7;
 
 module capsule_holder(ratio, transition, hollow = true) {
-    capsule_h = capsule_height + capsule_ring_h;
+    capsule_h = capsule_height;
     difference() {
-        // main capsule holder
+        // main capsule holder, use a conical bore to press fit the capsule
+        f = 0.05;
         cylinder(r = capsule_radius + fudge + wall, h = capsule_h, $fn = cfacets);
-        if (hollow) cylinder(r = capsule_radius + fudge, h = capsule_h + thin_mint, $fn = cfacets);
+        if (hollow) cylinder(r1 = capsule_radius + fudge - f, r2 = capsule_radius + fudge, h = capsule_h + thin_mint, $fn = cfacets);
     }
     // conical transition into core sphere
     transition_h = transition * capsule_radius;
@@ -192,7 +193,7 @@ module capsule_holder(ratio, transition, hollow = true) {
                 for (r = [0:36:179]) {
                     rotate([0, 90, r]) {
                         translate([-transition_h, 0, -capsule_radius - 2 * wall])
-                            scale([7, 1.3, 1]) cylinder(r = 1.0, h = (capsule_radius + 2 * wall) * 2, $fn = facets);
+                            scale([7, 1.25, 1]) cylinder(r = 1.0, h = (capsule_radius + 2 * wall) * 2, $fn = facets);
                     }
                 }
             }
@@ -202,7 +203,8 @@ module capsule_holder(ratio, transition, hollow = true) {
         translate([0, 0, hollow == false ? -3 : -lip_d]) {
             difference() {
                 // if not hollow make the ring longer to cut into core
-                cylinder(r = (capsule_radius) * ratio + wall + (hollow == true ? 0 : fit/2),
+                // cylinder(r = (capsule_radius) * ratio + wall + (hollow == true ? 0 : fit/2),
+                cylinder(r = (capsule_radius) * ratio + wall + (hollow == true ? 0 : 0),
                         h = hollow == true ? lip_d : 4.0, $fn = facets);
                 if (hollow) { cylinder(r = capsule_cable_diam/2 * 1.4, h = lip_d + thin_mint, $fn = facets); }
             }
@@ -212,7 +214,7 @@ module capsule_holder(ratio, transition, hollow = true) {
 
 // capsule holder array
 //
-module capsule_holder_array(hollow = true) {
+module render_octa_capsule_holder_array(hollow = true) {
     for (az = [45, 135, -45, -135]) {
         rotate([0, elev_angle, az]) {
             translate([0, 0, mic_radius - capsule_height]) {
@@ -233,33 +235,34 @@ module capsule_holder_array(hollow = true) {
 // render = 1: upper half
 // render = -1: lower half with stalk
 
-// thinkness of ring that connects both halves of the core sphere
+// thickness of ring that connects both halves of the core sphere
 core_ring_height = 5.0;
 
 // holes for screws that hold together both halves of the sphere
-module capsule_holder_screws(radius, wall) {
+module capsule_holder_screws(radius, wall, screw_r, shift = 0) {
     h_offset = 1.2;
         for (r = [90, 270]) {
             for (t = [0, 45]) {
                 m = t > 0 ? 1 : 0;
                 // 11.5 matches the angle for the flat shaves in the core
-                mirror([0, 0, m]) rotate([0, 11.5, r + t]) translate([-(radius + 2 * wall), 0, 0]) {
+                mirror([0, 0, m]) rotate([0, 11.5, r + t]) translate([-(radius + 2 * wall), 0, shift]) {
                     rotate([0, 90, 0]) {
-                        cylinder(r = 0.65, h = radius, $fn = facets);
+                        cylinder(r = screw_r, h = radius, $fn = facets);
                     }
                 }
             }
         }
 }
 
-// ring that holds the two halves of the sphere together
-module capsule_holder_ring(offset = 3.5) {
+// ring that connects the two halves of the core sphere
+module capsule_holder_ring(offset = 3.5, shift = 0) {
     s_radius = mic_radius - capsule_radius * (1 + transition_ratio) + offset;
     ring_h = core_ring_height - 0.2;
     translate([0, 0, -ring_h/2]) difference() {
         cylinder(r = s_radius - 2.5 * wall - fit, h = ring_h, $fn = facets);
         cylinder(r = s_radius - 4 * wall - fit, h = ring_h, $fn = facets);
-        translate([0, 0, ring_h/2]) capsule_holder_screws(s_radius, wall);
+        // shift the holes slightly so the two halves are pressed together
+        translate([0, 0, ring_h/2]) capsule_holder_screws(s_radius, wall, 0.65, shift);
     }
 }
 
@@ -273,7 +276,7 @@ module capsule_holder_core(top_radius, render = 0, offset = 3.5) {
                 sphere(r = s_radius, $fn = facets);
                 sphere(r = s_radius - 2.5 * wall, $fn = facets);
                 // holes for screws
-                capsule_holder_screws(s_radius, wall);
+                capsule_holder_screws(s_radius, wall, 0.9, 0.0);
                 // remove slice at the top
                 translate([-s_radius, -s_radius, s_radius - wall]) {
                     cube([2 * s_radius, 2 * s_radius, s_radius]);
@@ -334,7 +337,7 @@ module capsule_holder_core(top_radius, render = 0, offset = 3.5) {
             }
         }
         // make holes for capsule holders
-        capsule_holder_array(false);
+        render_octa_capsule_holder_array(false);
     }
     // index for aligning the two halves of core sphere
     rotate([0, 0, 22.5]) translate([s_radius, 0, 0]) {