Falcon Clamp V2

thingiverse

Falcon Clamp V2 - an alternate version leveraging gear cutting techniques from Parkinbot, utilizing Rudolf Huttary's method to facilitate profile shift and single-toothed gears. The tooth profile for a gear cut by another gear differs noticeably from that of a straight rack. This technique saves significant mathematical effort but comes with some drawbacks: compilation time and memory usage surge, and it is prone to crashing. To mitigate this, generate gears individually using the g parameter, then combine them in MeshLab (Flatten Visible Layers). The resulting meshes have an excessive number of small triangles and discretization artifacts; simplify by applying Quadratic Edge Collapse Decimation. One feature on my OpenSCAD wish list is a 2D simplification function or access to generated point arrays. This could be achieved by exporting intermediate 2D geometry, simplifying it in InkScape, and re-importing for extrusion. While this process is highly manual, I believe all these steps can be scripted. This example demonstrates the minimum size necessary; the next step is a vertically elongated version with alternating layers like a door hinge. At constant clamping pressure, force increases linearly along the full length of the clamp. This design could be adapted into a sheet metal bender, seamer, or hem tool.