Customizable Fan Grill Cover - Hacks

thingiverse

Use scad library from: https://www.thingiverse.com/thing:2802474 Add a random pattern module: module random_pattern(size, line_size, line_space) diff = (line_space / 10); seed=17; min_rad = (line_space / 2 * sqrt(3)) / 2 + line_size / 2; y_offset = sqrt(min_rad * min_rad * 4 - min_rad * min_rad); num_x = ceil(size / min_rad / 2) * 1.42; num_y = ceil(size / y_offset) * 1.42; difference() square([size * 1.42, size * 1.42], center=true); for(y=[floor(-num_y / 2) : ceil(num_y / 2)]) odd = (y % 2 == 0) ? 0 : min_rad; for(x=[floor(-num_x / 2) : ceil(num_x / 2)]) translate([x * min_rad * 2 + odd, y * y_offset]) rotate(30) single_rand = rands(4,9,1)[0]; circle(d=line_space-diff, $fn=single_rand); Add a free pattern module: module free_pattern(size, line_size, line_space, fn_pattern) diff = (line_space / 10); min_rad = (line_space / 2 * sqrt(3)) / 2 + line_size / 2; y_offset = sqrt(min_rad * min_rad * 4 - min_rad * min_rad); num_x = ceil(size / min_rad / 2) * 1.42; num_y = ceil(size / y_offset) * 1.42; difference() square([size * 1.42, size * 1.42], center=true); for(y=[floor(-num_y / 2) : ceil(num_y / 2)]) odd = (y % 2 == 0) ? 0 : min_rad; for(x=[floor(-num_x / 2) : ceil(num_x / 2)]) translate([x * min_rad * 2 + odd, y * y_offset]) rotate(30) circle(d=line_space-diff, $fn=single_rand); and modify fan_cover module adding new pattern modules: if(grill_pattern == "random") random_pattern(cover_size, line_size, line_space); else if(grill_pattern == "honeycomb") .... ... else free_pattern(cover_size, line_size, line_space, grill_pattern); For use free_pattern, grill_pattern var will be a number >= 3 (not a string) Another interesting hack is introduce spherical projection to the pattern: // scale intersection (projection) with the sphere scale([1,1,0.2]) intersection() { difference() { sphere(d=cover_size - min_border_size ); sphere(d=cover_size - min_border_size * 3); }; } // add cover_size to original linear_extrude height linear_extrude(height = grill_pattern_h+cover_size, convexity = 20) { .... } With the spherical projection, you can apply some scale on linear_extrude + eliminate the second sphere (which eliminate the hole) and you obtain funnels for air dispersion (Example 11,12 or 13) difference() { sphere(d=cover_size - min_border_size ); *sphere(d=cover_size - min_border_size * 3); // eliminate the hole }; linear_extrude(height = grill_pattern_h+cover_size, convexity = 20 , scale=1.5) // add scale for dispersion {.... Finally, add some twist effects and get something like example 14: linear_extrude(height = grill_pattern_h+cover_size, convexity = 20, scale=1.5 , twist = -50, slices=100) // add twist efect {