shell: make the print tools version-agnostic and document the version…

shell/README.md

@@ -0,0 +1,25 @@
+# Snips shell
+
+One folder per board/shell revision. Keep old versions; start the next one by copying the folder.
+
+```
+shell/<version>/
+  fusion/SnipsShell.f3d            the Fusion master (plus lib.py, sc_*.json used by the rebuild scripts)
+  export/stl, export/step          raw per-part exports from Fusion (as modelled)
+  export/print/stl, print/step     print-ready files (oriented, on Z=0), README.md, tools/
+  export/reference/                non-printing reference parts
+  export/_export_log.txt
+  photos/
+PCB/step/<version>/snips_controller.step   the board model for that revision (v1.1, v1.2)
+```
+
+## Exporting from Fusion
+Write to `shell/<version>/export/` (use the version the Fusion doc belongs to), per component:
+`createSTEPExportOptions(.../export/step/<Part>.step, comp)`, `createSTLExportOptions(comp, .../export/stl/<Part>.stl)`
+(high refinement, binary), and `createFusionArchiveExportOptions(.../fusion/SnipsShell.f3d)`.
+Then regenerate the print files (below).
+
+## Print files
+The tools in `export/print/tools/` find their folders from their own location, so run them from that version's
+`tools/` folder and they read `export/stl|step` and write `export/print/stl|step`. Override with
+`SNIPS_EXPORT_DIR` / `SNIPS_PRINT_DIR` if the files live somewhere else. See `export/print/README.md`.

shell/v1.1/export/print/README.md

@@ -6,7 +6,7 @@ Designed for a **0.4 mm nozzle**, ~0.2 mm layers.
 | Part | Orientation | Supports |
 |---|---|---|
 | TopShell | seam rim on the bed (as modelled), one piece (no split) | slicer supports for the roof, or use `TopShell_with_buck.stl` (see Support blocks) |
-| BottomShell | flipped, rim on the bed, belly up | slicer supports for the belly (interior scarring OK). The alignment lip now stops 1.2 mm above the bed plane, so it needs support under its top edge too (supports everywhere, not just touching build plate) |
+| BottomShell | flipped, rim on the bed, belly up | slicer supports for the belly (interior scarring OK). The alignment lip is level with the screw mounts (top at z 1.99), so the rim, lip and mounts all sit on the bed |
 | BatteryPanel | flat, belly (outer face) on the bed, cradle up; the snap arms flex in the bed plane | none needed (the front hook tabs are short; add a little support under them if your slicer complains) |
 | BumperCap | flat front face on the bed (face down) | slicer supports, small: under the side flange ties (about 2.4 mm wide overhang each side). New simple design: a flat button (34 x 6.7 mm) that goes through the window from INSIDE before the PCB, with a flange on each side behind the front wall and a 4.5 mm post on each flange |
 | Trigger | on its side, the +X arm face down, spring ear (the little block with the wire channel) up | none needed (`Trigger.stl`). The ear has a 45 deg gusset, and the only overhangs left are tiny bridges inside the 0.6 mm wire channel (about 6 mm2) |
@@ -21,7 +21,7 @@ Designed for a **0.4 mm nozzle**, ~0.2 mm layers.
 - TopShell: 10 blocks: the big one in the main cavity (about 13.5 cm3), one by the posts (about 3.4 cm3), and 8 small ones around the face buttons and under the thumbstick (side strips, between the button columns, beside and behind the stick; 0.5 to 2.3 cm3 each, all at least 0.3 mm from the part). The one out front under the OLED housing was dropped (`--max-y 50`). BottomShell: 2 side blocks (about 4 cm3 each).
 - Each block keeps 0.3 mm or more from the part on every side, and its flat top is lifted to about 0.2 mm under the lowest roof point above it. The sloped parts of the roof, and everything else, still use normal slicer supports.
 - In OrcaSlicer load the STL and answer yes to "split into parts". Give the block parts 1 wall and about 5% infill, no supports.
-- Regenerate with `tools/gen_buck.py <bare print stl> <out stl> [--max-y 50] [--band -20.5 22.5]` (`--band` adds the small face-button/thumbstick blocks; TopShell uses both flags) (needs numpy, scipy, scikit-image, trimesh, rtree).
+- Run the tools from this version's `tools/` folder; they find `export/stl|step` and `print/` from their own location (override with `SNIPS_EXPORT_DIR` / `SNIPS_PRINT_DIR`). Regenerate with `tools/gen_buck.py <bare print stl> <out stl> [--max-y 50] [--band -20.5 22.5]` (`--band` adds the small face-button/thumbstick blocks; TopShell uses both flags) (needs numpy, scipy, scikit-image, trimesh, rtree).
 
 ## Built-in breakaway supports
 - Tapered pillars: 1.0 mm base, 0.6 mm tip (0.7/0.5 mm in tight spots), ending 0.2 mm below the part so they snap off.

shell/v1.1/export/print/tools/build_sup.py

@@ -1,7 +1,8 @@
 import numpy as np, os, json, math
 import orient as O, gen_supports as G
 from scipy import ndimage
-d='/mnt/user-data/uploads/SnipsControllers/shell/export/stl'
+import paths as P
+d=P.SRC_STL
 GAP=0.2; BASE_W=1.0; TIP_W=0.6
 def pillar_mesh(x,y,z0,z1,bw=None,tw=None):
     h0=(bw or BASE_W)/2; h1=(tw or TIP_W)/2

shell/v1.1/export/print/tools/export_print.py

@@ -1,8 +1,9 @@
 import numpy as np, os, struct, json
 import orient as O, build_sup as B
 import trimesh
-src='/mnt/user-data/uploads/SnipsControllers/shell/export/stl'
-out='/mnt/user-data/outputs/print/stl'; os.makedirs(out,exist_ok=True)
+import paths as P
+src=P.SRC_STL
+out=P.OUT_STL; os.makedirs(out,exist_ok=True)
 ORI={'TriggerPost':'-Z up (flipped)','TopShell':'+Z up (as modelled)','BottomShell':'-Z up (flipped)','BatteryPanel':'+Z up (as modelled)','BumperCap':'+Y up','Trigger':'-X up'}
 for n in ['HallBridge','PowerPlate']+['FaceCap%d'%i for i in range(1,7)]: ORI[n]='+Z up (as modelled)'
 ORI['PowerPlate']='+Y up'

shell/v1.1/export/print/tools/gen_supports.py

@@ -54,7 +54,8 @@ def pillars(tris, R, cell=0.3, pitch=2.4, edge_margin=0.6):
     return out, zmin
 
 if __name__ == '__main__':
-    d = '/mnt/user-data/uploads/SnipsControllers/shell/export/stl'
+    import paths as P
+    d = P.SRC_STL
     jobs = {'BumperCap': '-Z up (flipped)', 'Trigger': '-X up'}
     res = {}
     for n, o in jobs.items():

shell/v1.1/export/print/tools/paths.py

@@ -0,0 +1,15 @@
+"""Where the print tools read and write. Everything is derived from this file's location, so the tools in
+shell/<version>/export/print/tools/ always work on that version's files.
+
+  EXPORT  shell/<version>/export          (raw Fusion exports: stl/, step/)
+  PRINT   shell/<version>/export/print    (print-ready output: stl/, step/)
+
+Override for a scratch checkout or a container with SNIPS_EXPORT_DIR / SNIPS_PRINT_DIR."""
+import os
+HERE = os.path.dirname(os.path.abspath(__file__))
+EXPORT = os.environ.get('SNIPS_EXPORT_DIR') or os.path.normpath(os.path.join(HERE, '..', '..'))
+PRINT = os.environ.get('SNIPS_PRINT_DIR') or os.path.normpath(os.path.join(HERE, '..'))
+SRC_STL = os.path.join(EXPORT, 'stl')
+SRC_STEP = os.path.join(EXPORT, 'step')
+OUT_STL = os.path.join(PRINT, 'stl')
+OUT_STEP = os.path.join(PRINT, 'step')

shell/v1.1/export/print/tools/step_orient.py

@@ -1,8 +1,9 @@
 import os
 from build123d import import_step, export_step, Pos, Rot
 import export_print_cfg as C
-src='/mnt/user-data/uploads/SnipsControllers/shell/export/step'
-out='/mnt/user-data/outputs/print/step'; os.makedirs(out,exist_ok=True)
+import paths as P
+src=P.SRC_STEP
+out=P.OUT_STEP; os.makedirs(out,exist_ok=True)
 RR={'+Z up (as modelled)':Rot(0,0,0),'-Z up (flipped)':Rot(X=180),'-Y up':Rot(X=90),'+Y up':Rot(X=-90),'-X up':Rot(Y=-90),'+X up':Rot(Y=90)}
 for n,o in C.ORI.items():
     s=RR[o]*import_step(os.path.join(src,n+'.step'))