add initial 12 capsule design to repository

BigSpHEAR.scad

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+//
+// BigSpHEAR (Big Spherical Harmonics Ear), 12 capsule Ambisonics microphone
+//
+// Copyright 2015, Fernando Lopez-Lezcano, All Rights Reserved
+// nando@ccrma.stanford.edu
+//
+//
+//  This program is free software: you can redistribute it and/or modify
+//  it under the terms of the GNU General Public License as published by
+//  the Free Software Foundation, either version 3 of the License, or
+//  (at your option) any later version.
+//
+//  This program is distributed in the hope that it will be useful,
+//  but WITHOUT ANY WARRANTY; without even the implied warranty of
+//  MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
+//  GNU General Public License for more details.
+//
+//  You should have received a copy of the GNU General Public License
+//  along with this program.  If not, see <http://www.gnu.org/licenses/>.
+//
+//
+// 3d Models released under the Creative Commons license as follows:
+//   Attribution-NonCommercial-ShareAlike 4.0 International (CC BY-NC-SA 4.0)
+// http://creativecommons.org/licenses/by-nc-sa/4.0/
+
+
+////
+//// model parameters
+
+// dimensions of the EM182 electret microphone
+capsule_radius = 5;
+capsule_height = 4.5;
+
+// distance between face of capsule and center of array
+mic_radius = 20;
+
+// dimensions of capsule holder connection legs
+leg_width = 4;
+leg_thick = 2.5;
+
+// width of the ridge that connects to the mount
+ridge_width = 2;
+ridge_length = 2;
+
+// wall thickness of capsule holder
+wall = 1;
+
+// dimensions of microphone holder
+mount_radius = 4.5;
+
+// height of mount
+mount_height = 4;
+
+// type of octathingy
+// 0 -> regular octathingy (equilateral triangles in the square antiprism)
+// 1 -> tetrahedral compatible octathingy (same elevation angle as the tetrahedral mic)
+tetra_compat = 0;
+
+//// end of model parameters
+////
+//// rendering control
+
+// what to render:
+// 0 -> ready to print
+//   set = 0 -> one capsule, set = 1 -> four capsules
+// 1 -> the whole microhone with four capsules
+rendermic = 1;
+renderset = 0;
+
+// what type of connection to use between capsule holders:
+// 0 -> original cylinder beams
+// 1 -> interlocking beams (out)
+// 2 -> interlocking beams (in)
+connect = 1;
+
+// adjustment for the radius of the capsule
+//   measured inside diameter of a trial print was around 7.5 to 8.2 
+//   instead of 10, capsule diameter was 9.99)
+fudge = 0.15;
+
+// adjustment for fit of slots in connection legs and mount
+fit = 0.2;
+
+// number of facets for rendering cylinders
+facets = 64;
+
+//// end of rendering control
+////
+
+// define the elevation angle of the upper and lower rings
+//
+// http://eusebeia.dyndns.org/4d/antiprism4
+//
+// The Cartesian coordinates of the square antiprism, 
+// centered on the origin and having edge length 2, are:
+//
+//    (0, ±√2, 1/∜2)
+//    (±√2, 0, 1/∜2)
+//    (±1, ±1, −1/∜2)
+//
+// the elevation angle for the two rings of 4 is:
+//
+// 1/2*∜2 = 0.420448207627 (z for edge length = 1)
+// atan(1/(2*∜2) / 0.707) = 30.7358671024
+elev_angle =  tetra_compat == 0 ? atan(1 / (2 * sqrt(sqrt(2))) * sqrt(2)) : atan(sqrt(1/2));
+
+// calculate half angle between vertices in the square antiprism
+// these angles define the length of the connecting legs
+//
+// z coordinate of antiprism vertices
+vert_z = sqrt(2) * tan(elev_angle) / 2;
+// vector length (same for all antiprism vertices)
+vert_n = norm([-0.5, -0.5, vert_z]);
+// half angle between adjacent vertices in either the upper or lower rings
+vert_angle_h = acos(([-0.5, -0.5, vert_z] / vert_n) * ([0.5, -0.5, vert_z] / vert_n)) / 2;
+// half angle between adjacent vertices in the upper and lower rings
+vert_angle_v = acos(([0.0, -1 / sqrt(2), -vert_z] / vert_n) * ([0.5, -0.5, vert_z] / vert_n)) / 2;
+
+// microphone holder geometry
+capsule_sep_min = (mic_radius - capsule_height) * cos(elev_angle) - (capsule_radius + wall) * sin(elev_angle);
+capsule_sep_max = mic_radius * cos(elev_angle) - (capsule_radius + wall) * sin(elev_angle);
+capsule_bottom = mic_radius * sin(elev_angle) + (capsule_radius + wall) * cos(elev_angle);
+mount_slot_depth = ridge_length * sin(elev_angle);
+
+////////
+// microphone capsule holder
+
+// azimuth: horizontal orientation of the capsule
+// elevation: vertical orientation of the capsure
+// mounts: vectors containing the angle of the mount and the angle to the adjacent capsule
+// twist: rotate the whole capsule to match mounting legs
+
+module capsule (azimuth, elevation, mounts, twist, ridge) {
+	rotate([0, 0, azimuth]) {
+		rotate([0, (90 - elevation), 0]) {
+  			translate([0, 0, rendermic == 0 ? 0 : mic_radius - capsule_height]) {
+				difference () {
+					union () {
+						// main capsule holder
+						cylinder(r = capsule_radius + wall, h = capsule_height, $fn = facets);	
+						// the mounting legs
+						for (angles = mounts) {
+							rotate([0, 0, angles[0] + twist]) {
+								// connect with cylindrical beams, very pretty
+                                leg_length = mic_radius * sin(angles[1]) - (capsule_radius + wall) * cos(angles[1]) + wall;
+								if (connect == 0) {
+									translate([capsule_radius - wall, 0, capsule_height - wall]) {
+										rotate([0, 180 - (90 - angles[1]), 0]) {
+											cylinder(d = leg_width, h = leg_length - 0.1, center = false, $fn = facets);
+										}
+									}
+								}
+								// connect with horizontal legs
+								if (connect == 1) {
+                                    leg_length = (mic_radius - capsule_height + leg_thick) * tan(angles[1]) - capsule_radius;
+                                    slot_depth = leg_thick * cos(90 - 2 * angles[1]) + fit;
+									translate([capsule_radius + leg_length + fudge, - leg_width / 3, 0]) {
+										rotate([0, -90, 0]) {
+											difference() {
+												// thickness, width
+												cube([leg_thick, leg_width, leg_length]);
+												// cut slot in connector
+												translate([0, leg_width / 3 - (fit / 2), 0]) {
+													cube([leg_thick, leg_width / 3 + fit, slot_depth]);
+												}
+											}
+										}
+									}
+								}
+								// connect with vertical legs
+								if (connect == 2) {
+                                    leg_length = (mic_radius * tan(angles[1]) - capsule_radius) * tan(90 - angles[1]); 
+                                    slot_depth = leg_thick * (cos (90 - 2 * angles[1]) + tan(90 - 2 * angles[1])) + fit;
+									translate([capsule_radius + fudge, - leg_width / 3, - leg_length + capsule_height]) {
+										difference() {
+											// thickness, width
+											cube([leg_thick, leg_width, leg_length]);
+											// cut slot in connector
+											translate([0, leg_width / 3 - (fit / 2), 0]) {
+												cube([leg_thick, leg_width / 3 + fit, slot_depth]);
+											}
+										}
+									}
+								}
+							}
+						}
+						// add ridges for microphone mount
+						if (ridge == 1) {
+							rotate([0, 0, twist]) {
+								translate([capsule_radius + fudge, - wall , 0]) {
+									difference() {
+										cube([ridge_length, ridge_width, capsule_height], center = false);
+										//rotate([0, 90 - elev_angle, 0]) {
+										//	cube([ridge_length, ridge_width, capsule_height], center = false);
+										//}
+									}
+								}
+							}
+						}
+					}
+					// make the hole for the capsule
+					translate ([0, 0, -2]) {
+						cylinder(r = capsule_radius + fudge, h = capsule_height + 2, $fn = facets);
+					}
+					// remove any extra connecting beam material from the face of the holder
+					if (connect == 0) {
+						translate ([0, 0, capsule_height]) {
+							cylinder(r = capsule_radius + wall * 2, h = 2, $fn = facets);
+						}
+					}
+				}
+			}
+		}
+	}
+}
+
+// microphone mount
+//
+// angles: angles for mount slots
+// wall: thickness of cylinder wall
+// separation: height of mount with respect of the microphone assembly
+
+module mount (angles, wall, separation) {
+	translate([0, 0, -(separation + 0.1)]) {
+		difference() {
+			union() {
+				// grips for the capsule holder ridge
+				for (rot = angles) {
+					rotate([0, 0, rot]) {
+						translate([-capsule_sep_max, -(ridge_width - fit / 2), -mount_height]) {
+							cube([capsule_sep_max, ridge_width * 2 - fit, mount_height]);
+                            rotate([0, -elev_angle, 0]) {
+                                cube([capsule_sep_max, ridge_width * 2 - fit, mount_height * cos(elev_angle)]);
+                            }
+						}
+					}
+				}
+				translate([0, 0, -mount_height]) {
+					cylinder(r = mount_radius + wall, h = mount_height, $fn = facets);
+				}
+			}
+			// make the hole for the mount (* 2 to cut the ridge as well)
+			translate([0, 0, -mount_height]) {
+				cylinder(r = mount_radius, h = mount_height * 2, $fn = facets);
+			}
+            // cut the outside of the sloped ridge
+			translate([0, 0, -mount_height]) {
+                difference() {
+                    cylinder(r = capsule_sep_max + mount_height * 2, h = mount_height * 2, $fn = facets);
+                    cylinder(r = capsule_sep_max, h = mount_height * 2, $fn = facets);
+                }
+			}
+			// and cut a slot for the ridges in the wall of the cylinder
+            for (rot = angles) {
+                rotate([0, 0, rot]) {
+                    translate([-capsule_sep_max * 2, -ridge_width + 4 * fit, -mount_slot_depth]) {
+                        cube([capsule_sep_max * 2, ridge_width + 2 * fit, mount_height * 2]);
+                    }
+                }
+			}
+		}
+	}
+}
+
+elev = atan(1/2);
+
+golden = (1 + sqrt(5)) / 2;
+diedral = 90 - (2 * atan(golden) / 2);
+
+leg_angles = 
+    [
+        [0, diedral], 
+        [72, diedral],
+        [144, diedral],
+        [216, diedral],
+        [288, diedral]
+    ];
+
+// render a complete microphone
+if (rendermic == 1) {
+    for (azup = [0 : 72 : 360]) {
+        capsule(azup, elev, leg_angles, 36, 0);
+    }
+    for (azdn = [36 : 72 : 360]) {
+        capsule(azdn, -elev, leg_angles, 0, 0);
+    }
+    capsule(0, 90, leg_angles, 0, 0);
+    capsule(0, -90, leg_angles, 0, 0);
+}
+																		    
+// print all the parts separately
+part_sep = capsule_radius * 5;
+if (rendermic == 0) {
+    if (connect == 1) {
+        twist_all = -36;
+        translate([0, 0, 0]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        translate([0, part_sep, 0]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        translate([part_sep, 0, 0]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        translate([part_sep, part_sep]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        translate([-part_sep, 0, 0]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        translate([-part_sep, part_sep]) { capsule(0, 90, leg_angles, twist_all, 0); }
+        // ridges to connect all parts
+        translate([-part_sep + wall, part_sep / 2 - wall, 0]) {
+            cube([part_sep * 2, wall, wall / 2]);
+        }
+        for (d = [-part_sep, 0, part_sep]) {
+            translate([wall + d, capsule_radius, 0]) {
+                cube([wall, part_sep - capsule_radius * 2, wall / 2]);
+            }
+        }
+    }
+}
+