GETTING STARTED

1. Download & Install OpenSCAD (free; open-source)

   • www.OpenSCAD.org/downloads.html
   • Open the Program



2. Obtain the Extruded Element Library to open with OpenSCAD

   • Github Repository:
     • https://github.com/ExtrudedElement/eellc_lib/tree/master
   • Raw Text file for quick copy & paste (ctrl + A-> ctrl + C)
     • https://raw.githubusercontent.com/ExtrudedElement/eellc_lib/master/eellc_lib.scad

3. Open the eellc_lib.scad Extruded Element Library with OpenSCAD

   • Or paste its contents into the OpenSCAD Editor

4. Press F6 to Render the Tessellation (array/tiling) of Interlocking Shapes

   • • The current active “EXECUTED CODE” is the module called “Tessellate” as shown above.

5. Adjust the Extruded Element Parameters

   • Press F6 After each Change to Observe the Effect. (READ GREY COMMENTS IN TEXT FILE FOR DESCRIPTION)
   • Parameters are located below license and patent information at the top of the code
   • Parameter Names (red underline; above) describe the parameter
   • Parameter Values (green dotted line; above) describe the possible values if necessary
   • Parameters without possible values (such as s_h, hook size) can be tinkered with

6. Extrude the Element Tessellation

   • Scroll to  “EXECUTED CODE” Marked by // ( ) ( ) ( ) ( ) . . .
   • [Red Box] Add two back-slashes ‘//’ to the tessellate(); line
     • (“Comment out” the tessellate line)
   • [Green Box] Delete the two back-slashes ‘//’ from the linear_extrude… …tessellate(); line
     • (“Uncomment” the linear_extrude line)

OBJECT INCORPORATION

1. Save the OpenSCAD file you are working in (suggested “eellc_lib.scad”)

2. Save an Object (.STL file) in the Same Directory as eellc_lib.scad

   • Import the object file from any of your favorite sources for 3D Printable objects (.stl files).

3. In OpenSCAD text editor, Change the Filename to match your object

   • The fileName parameter can be found under ****Imported STL Object options****



4. Observe the Orientation and Array Size of Extruded Elements

   • In the Above image, the array is the X-Y Plane (Green & Red axes), and the extrusion direction is parallel to the Z-Axis (Blue axis)
   • The array above spans about 300 X 300 Units (here considered them mm, for the sake of 3D printing)

5. Import the Object

   • Comment out (type leading “//” on) the linear_extrude… …tessellate(); line
   • Uncomment (delete leading “//” on) the following line: translate… …import(fileName);

6. Scale & Align the Object to the Extruded Element Array

   • In the parameters sections (above “Executed Code”) modify the ****Imported STL Object options**** parameters.
   • The Element Array may need to be increased in size to envelope your object (parameters n_elem & m_elem; along x & y axes, respectively)
   • Uncommenting the linear_extrude… …tessellate(); line will enable object and element array visualization simultaneously.
     • WARNING: process time after pressing F6 will be much longer than with the object or element array alone.
   • CONGRATULATIONS!!! You are now ready to start production processes.

PRODUCTION PREPARATION

1. Adjust Hook Kerf for Hook Fitment

   • In ****Clearance/Fitment Options**** section of parameters locate k_h and adjust for hook fitment
     • k_h = 1, specifies exact match of hooks; no clearance.
     • k_h < 1, specifies a percent of hook tip width to shrink for clearance (0.98 = 98% of hook tip width)

2. Adjust Element Kerf for Element Fitment (Solid Elements only; e_fill set to 1 or -1)

   • In ****Clearance/Fitment Options**** section of parameters locate k_e and adjust for element boundary fitment
   • k_e = 1, specifies exact match of element boundaries; no clearance.
   • k_e < 1, specifies the element boundary clearance (a relative percent of hook tip width)
     • e.g. k_e=0.98; element boundary clearance  = 100-98%, 2% of hook tip width)
     • When k_h & k_e are set to the same value, the gap will be uniform.

PRODUCTION TESTING

1. Generate Sample Hooks

   • In “EXECUTED CODE” Section, comment-out all VISUALIZATION lines [red box; above]
     • comment out any of:
       • tessellation();
       • linear_extrude… …tessellation();
       • translate… …import(fileName);
   • Uncomment  sample_hooks(); line [green box; above]
   • TIP: CLICK THE MAGNIFYING GLASS ICON TO RE-LOCATE YOUR F6-RENDERED SOLID [ORANGE BOX; ABOVE]




2. Export file of Sample Hook Pair

   • In OpenSCAD: Go to File->Export and slect your preferred format
     • (.STL is common for 3D Printing)




3. Repeat Production Preparation & Testing until Satisfied

   • Produce your sample hooks with your favorite rapid prototyping method
     • Additive Manufacturing (set Kerf values < 1)
     • Conventional Manufacturing (set Kerf values >/= 1; disregarding tool-comp)

4. Generate Sample Elements

   • Comment out sample_hooks(); line
   • Uncomment sample_elements(); line
   • POSITION NOTE: Adjust the separation of sample elements with printer_spacing parameter in above parameter section.
   • SINGLE ELEMENT NOTE: If only one element is desired for fabrication:
     • Set n_elem & m_elem = 1
     • Utilize the “EXECUTED CODE” ->”VISUALIZATION”  line – linear_extrude… …tessellate();




5. Export, Test & Repeat

PRODUCTION

1. Complete Above Steps Satisfactorily

   • Ensure the Imported Object is aligned with the element array
   • Ensure the hooks fit as desired
   • Ensure the elements fit as desired (if using e_fill = -1 or 1)
   • Ensure the element array completely encapsulates your object
     • by adjusting parameters:
       • height
       • n_elem
       • m_elem

2. Set-up Batch File to Individually Generate all Elements Intersecting the Imported object

   • Extruded Element Library has an example at the bottom of the code [Green Box; above]
   • For Windows Users-
     • Copy the Batch File text into a Notepad document and Save as ‘Something’.bat (exclude /* and */ above and below for-loop)
   • For all other OS, refer to OpenSCAD Documentation:
     • https://en.wikibooks.org/wiki/OpenSCAD_User_Manual/Using_OpenSCAD_in_a_command_line_environment

3. Edit the Batch File to Meet your File Name, Directory, & Array Size

   • Change the directory path [Orange Box] to match the directory where you have stored the *.stl object file and the *.scad extruded element library
   • Change the values described by the white boxes above
     • # of Elements -1:
       • frisbee example had n_elem = 15 & m_elem = 15
       • 15 x 15 – 1 = 224
     • Prefered Prefix:
       • for frisbee example I would use: “frisbee-“
     • Name of Saved *scad file:
       • whatever you named your *.scad file in your working directory

SHARE YOUR WORK

1. Share your creations at the below social networking sites
2. Subreddit: r/ExtrudedElement is set-up just for this purpose and to include troubleshooting and tips or updates from the community
   • www.reddit.com/r/ExtrudedElement