even more tuning of capsule holder for test rig, thicker back plate for less flex, move contacts around a bit - we may need to decrease the diameter of the holder as the capsule should have a tighter fit as the contact springs push the capsule out

TestRig.scad

@@ -52,13 +52,16 @@ contact_border = 0.5;
 contact_offset = 0.3;
 
 // cutout offset from edge of capsule
-contact_cutout = 1.7;
-contact_cutout_gnd = 2.2;
+contact_cutout = 2.2;
+contact_cutout_gnd = 2.5;
 
 // support depth
 disk_depth = 0.9;
 disk_edge = 0.49;
 
+// thinkness of sleeve
+sleeve_edge = 0.66;
+
 // adjustment for the inner radius of the capsule holder
 //   measured inside diameter of a trial print was around 7.5 to 8.2 
 //   instead of 10, capsule diameter was 9.99)
@@ -82,9 +85,9 @@ module contact (trans, angle, cutout, slot = false) {
                             cube([contact_width, capsule_radius + wall / 2, disk_depth]);
                         }
                         // cutout for clip from edge of disk
-                        translate([contact_width, capsule_radius - cutout, 0]) {
-                            cylinder(r = contact_width / 2 * 1.25, h = disk_depth, $fn = facets);
-                            //cube([contact_width, 0.8, disk_depth]);
+                        translate([contact_width / 2, capsule_radius - cutout, 0]) {
+                            cube([contact_width, contact_width, disk_depth]);
+                            //cylinder(r = contact_width / 2 * 1.25, h = disk_depth, $fn = facets);
                         }
                     }
                 } else {
@@ -93,9 +96,9 @@ module contact (trans, angle, cutout, slot = false) {
                         // channel for clip
                         cube([contact_width, capsule_radius + wall, disk_depth]);
                     }
-                    translate([contact_width, capsule_radius - cutout, 0]) {
-                        //cube([contact_width, 0.8, disk_depth]);
-                        cylinder(r = contact_width / 2 * 1.25, h = disk_depth, $fn = facets);
+                    translate([contact_width / 2, capsule_radius - cutout, 0]) {
+                        cube([contact_width, contact_width, disk_depth]);
+                        //cylinder(r = contact_width / 2 * 1.25, h = disk_depth, $fn = facets);
                     }
                 }
             }
@@ -105,7 +108,7 @@ module contact (trans, angle, cutout, slot = false) {
 
 
 // main capsule holder
-translate([capsule_radius * 3.0, capsule_radius * 3, 0]) {
+*translate([capsule_radius * 3.0, capsule_radius * 3, 0]) {
     difference() {
         cylinder(r = capsule_radius + wall, h = capsule_height, $fn = facets);
         cylinder(r = capsule_radius + fudge, h = capsule_height, $fn = facets);
@@ -114,7 +117,7 @@ translate([capsule_radius * 3.0, capsule_radius * 3, 0]) {
 
 
 // back plate with contact springs
-difference() {
+*difference() {
     union() {
         difference() {
             union() {
@@ -159,17 +162,17 @@ translate([capsule_radius * 3 , 0, 0]) {
         cylinder(r = capsule_radius + wall, h = capsule_height * 2 / 3, $fn = facets);
     }
     difference() {
-        cylinder(r = capsule_radius + wall, h = disk_edge, $fn = facets);
-        cylinder(r = capsule_radius, h = disk_edge, $fn = facets);
+        cylinder(r = capsule_radius + wall, h = sleeve_edge, $fn = facets);
+        cylinder(r = capsule_radius, h = sleeve_edge, $fn = facets);
     }
     // back plate for contacts 1 / 2
-    translate([-(contact_width + 2 * contact_border), capsule_radius / 2, 0]) {
-        cube([(contact_width + 2 * contact_border) * 2, capsule_radius / 2, disk_edge]);
+    translate([-(contact_width + 2 * contact_border) + 0.1, capsule_radius / 2 - 0.3, 0]) {
+        cube([(contact_width + 2 * contact_border) * 2 - 0.2, capsule_radius / 2 + 0.3, sleeve_edge]);
     }
     // back plate for GND contact
     rotate([0, 0, 90]) {
         translate([-(contact_width + 2 * contact_border), capsule_radius * 1 / 3, 0]) {
-            cube([(contact_width + 2 * contact_border), capsule_radius * 2 / 3, disk_edge]);
+            cube([(contact_width + 2 * contact_border), capsule_radius * 2 / 3, sleeve_edge]);
         }
     }
 }