added rough sketch/prototype resembling what i actually built

assembly.scad

@@ -58,23 +58,24 @@ grid_size_x_gridunits = grid_elements(grid_size_x_mm, 1);
 grid_size_y_gridunits = grid_elements(grid_size_y_mm, 1);
 for(xy = grid(grid_size_x_gridunits, grid_size_y_gridunits, 1, 1)){
     translate([
-        LEG_OFFSET_X + LEG_BASE_DIAMETER,
+        FRAME_MAJOR_STRUT_WIDTH + (MODULE_RAIL_BASE_WIDTH / 2),
         MODULE_RAIL_MARGIN_SCREW,
         MAIN_HEIGHT - MODULE_SCREW_LENGTH
     ]) {
-        translate(xy) { screw_hole(); }
+        //translate(xy) { screw_hole(); }
     }
 }
 
 // rack module placeholder
 translate([
-    200,
+    FRAME_MAJOR_STRUT_WIDTH + (MODULE_RAIL_BASE_WIDTH / 2),
     MODULE_RAIL_MARGIN_SCREW,
-    MAIN_HEIGHT - TOP_THICKNESS
+    _BELOW_FRAME
 ]) {
 
     rack_width_gridunits = grid_units_length(550);
-    rack_depth_gridunits = grid_units_length(650);
+    //rack_depth_gridunits = grid_units_length(650);
+    rack_depth_gridunits = grid_units_length(600);
     module_base(rack_width_gridunits, rack_depth_gridunits, 600, 3);
     module_rail_set(rack_width_gridunits, rack_depth_gridunits, 3);
 }

config.scad

@@ -19,16 +19,22 @@ COLOR_SEMANTIC_LOAD_BEARING = [1, 0.5, 0];
 
 // All measurements in mm
 // Outer measurements
-MAIN_WIDTH = 1800;
-MAIN_HEIGHT = 700;
+MAIN_WIDTH = 1400;
+MAIN_HEIGHT = 800;
 MAIN_DEPTH = 900;
 
 TOP_THICKNESS = 25;
 
 BACKPLATE_THICKNESS = 15;
+
+STAND_THICKNESS = 60;
 STAND_HEIGHT = 500;
-STAND_DEPTH = 150;
-STAND_THICKNESS = 20;
+STAND_DEPTH = 200;
+
+FRAME_THICKNESS = STAND_THICKNESS; // safe to change independently of STAND_THICKNESS
+//FRAME_MAJOR_STRUT_WIDTH = STAND_DEPTH; // safe to change independently of STAND_DEPTH, but MUST fit legs! TODO: Sanity check!
+FRAME_MAJOR_STRUT_WIDTH = 80; // safe to change independently of STAND_DEPTH, but MUST fit legs! TODO: Sanity check!
+FRAME_MINOR_STRUT_WIDTH = 20;
 
 CABLE_TRAY_HEIGHT = 150;
 CABLE_TRAY_LIP = 50; // backplate -> |_. <- lip
@@ -55,11 +61,9 @@ LEG_DIAMETER = 50;
 LEG_BASE_DIAMETER = 100;
 LEG_BASE_THICKNESS = 10;
 // offset of the legs' *center* not how far their bases are from edges!
-LEG_OFFSET_X = 100;
-LEG_OFFSET_Y = LEG_OFFSET_X;
 
-SIDETABLE_DEPTH = MAIN_DEPTH;
-SIDETABLE_WIDTH = MAIN_DEPTH * 2;
+SIDETABLE_DEPTH = MAIN_DEPTH; // safe to change independently of MAIN_DEPTH but can lead to module incompatibilities
+SIDETABLE_WIDTH = MAIN_DEPTH * 2; // safe to change independently of MAIN_DEPTH
 
 // Stuff from subs/base.scad
 GRID_SIZE = 50;
@@ -75,7 +79,6 @@ MODULE_RAIL_BASE_WIDTH = 50;
 MODULE_RAIL_MARGIN_SIDE = 5;
 MODULE_RAIL_MARGIN_TOP = 10; // MODULE_THICKNESS;
 MODULE_RAIL_MARGIN_SCREW = GRID_SIZE;
-_MODULE_RAIL_OFFSET = MODULE_RAIL_BASE_WIDTH / 2 + MODULE_RAIL_MARGIN_SIDE; // offset on x axis for modules cause by size of rail
 
 MODULE_SCREW_LENGTH = 120; // length WITHOUT the screw head
 SCREW_DIAMETER = 8;
@@ -88,14 +91,26 @@ BARREL_NUT_DIAMETER = 15;
  * These are considered "private" variables and MUST NOT be modified!
  */
 
-_BACKPLATE_HEIGHT = STAND_HEIGHT - STAND_THICKNESS;
+// helper vars for vertical dimensions
+_BELOW_TOP = MAIN_HEIGHT - TOP_THICKNESS;
+_BELOW_FRAME = _BELOW_TOP - FRAME_THICKNESS;
+_BELOW_STAND = _BELOW_FRAME - STAND_HEIGHT;
+
+// calculated element dimensions
+_BACKPLATE_HEIGHT = FRAME_THICKNESS + STAND_HEIGHT - STAND_THICKNESS;
 
 _CABLE_TRAY_WIDTH = MAIN_WIDTH - 2 * STAND_THICKNESS;
 _CABLE_TRAY_DEPTH = STAND_DEPTH - CABLE_TRAY_THICKNESS;
 _CABLE_TRAY_OFFSET_Y = MAIN_HEIGHT - TOP_THICKNESS - CABLE_TRAY_HEIGHT;
 
+_LEG_OFFSET = FRAME_MAJOR_STRUT_WIDTH / 2;
 
-_LEG_HEIGHT = MAIN_HEIGHT - TOP_THICKNESS;
-_FOOT_HEIGHT = MAIN_HEIGHT - TOP_THICKNESS - STAND_HEIGHT;
+LEG_OFFSET_X = _LEG_OFFSET;
+LEG_OFFSET_Y = _LEG_OFFSET;
+
+_LEG_HEIGHT = _BELOW_FRAME;
+_FOOT_HEIGHT = _BELOW_STAND;
 _FOOT_OFFSET_Y = MAIN_DEPTH - ((STAND_DEPTH + BACKPLATE_THICKNESS) / 2);
 _LEG_TO_FOOT = _FOOT_OFFSET_Y - LEG_OFFSET_Y;
+
+_MODULE_RAIL_OFFSET = MODULE_RAIL_BASE_WIDTH / 2 + MODULE_RAIL_MARGIN_SIDE; // offset on x axis for modules cause by size of rail

fiddling.scad

@@ -0,0 +1,219 @@
+$vpf = 65;
+
+// all measurements in mm
+LAYER_SPACE = 0; // space between sandwich layers in rendering
+LAYER_COUNT = 4; // used for misc calculations, updated by hands if you add/remove layers from the sandwich
+GRID_SIZE = 50;
+RACKUNIT = 45;
+BOARD_THICKNESS = 16;
+SANDWICH_HEIGHT = LAYER_COUNT * BOARD_THICKNESS;
+
+DESK_WIDTH = 1400;
+DESK_DEPTH = 800;
+DESK_TOP_OFFSET = 10; // offset between top desk plate and stand, so cables can be fit under fully mounted STAND_TOP_RACKUNITS
+
+FRAME = 80;
+STRUT_DEPTH = 40;
+STRUT_INTERVAL = 100; // must be multiple of 50 (i.e. grid size) to align with grid
+STRUT_OFFSET = 50 + (STRUT_DEPTH / 2);
+
+MAIN_SUPPORT_DEPTH = 600;
+
+STAND_DEPTH_INNER = 200;
+STAND_DEPTH_OUTER = STAND_DEPTH_INNER + BOARD_THICKNESS;
+STAND_WIDTH = DESK_WIDTH + ( 2 * BOARD_THICKNESS );
+STAND_TOP_RACKUNITS = 2;
+STAND_BOTTOM_RACKUNITS = 4;
+STAND_BELOW_SANDWICH = 550; // measurements 61.5-62cm leg-to-bottom-pipe, 7cm foot-to-bottom-pipe
+STAND_ABOVE_SANDWICH = RACKUNIT * STAND_TOP_RACKUNITS; // INNER height above the sandwich, i.e. how big a thing you can screw into the opening
+STAND_HEIGHT_INNER = STAND_BELOW_SANDWICH - BOARD_THICKNESS + SANDWICH_HEIGHT + STAND_ABOVE_SANDWICH;
+//                                          ↑ bottom board, important to fit STAND_BELOW_SANDWICH *with* the bottom board
+STAND_HEIGHT_OUTER = STAND_HEIGHT_INNER + ( 2 * BOARD_THICKNESS );
+
+
+function layer_y ( layer ) = layer * (BOARD_THICKNESS + LAYER_SPACE);
+
+module board(width, length) {
+    /*echo("----------------------------------------");
+    echo("Board:");
+    echo(width=width, length=length);
+    echo("----------------------------------------");*/
+    echo(width, " x ", length);
+    cube([width, length, BOARD_THICKNESS]);
+}
+
+module board_side(depth, height) {
+    /*echo("----------------------------------------");
+    echo("Board (side):");
+    echo(depth=depth, height=height);
+    echo("----------------------------------------");*/
+    echo(depth, " x ", height);
+    cube([BOARD_THICKNESS, depth, height]);
+}
+
+module board_back(width, height) {
+    /*echo("----------------------------------------");
+    echo("Board (back):");
+    echo(width=width, height=height);
+    echo("----------------------------------------");*/
+    echo(width, " x ", height);
+    cube([width, BOARD_THICKNESS, height]);
+}
+
+// layer 0
+board(FRAME, DESK_DEPTH);
+translate([DESK_WIDTH - FRAME, 0, 0]){
+    board(FRAME, DESK_DEPTH);
+}
+
+// layer 1
+translate([0, 0, layer_y(1)]){
+
+    // bottom board with grid
+    board(DESK_WIDTH, DESK_DEPTH - STAND_DEPTH_INNER);
+
+    // small left/right frame pieces to make sandwhich sides seamless (i.e. no holes in vertical space)
+    translate([0, DESK_DEPTH - STAND_DEPTH_INNER]){
+        color("orange"){
+            board(FRAME, STAND_DEPTH_INNER);
+            translate([DESK_WIDTH - FRAME, 0, 0]){
+                board(FRAME, STAND_DEPTH_INNER);
+            }
+        }
+    }
+}
+
+// layer 2
+translate([0, 0, layer_y(2)]){
+
+    // main left/right frame pieces
+    board(FRAME, DESK_DEPTH);
+    translate([DESK_WIDTH - FRAME, 0, 0]){
+        board(FRAME, DESK_DEPTH);
+    }
+
+    // struts
+    translate([FRAME / 2, STRUT_OFFSET]) {
+        color("orange"){
+            for (offset=[0:STRUT_INTERVAL:DESK_DEPTH - STAND_DEPTH_INNER - STRUT_OFFSET - STRUT_DEPTH]) {
+                translate([0, offset]){
+                    board(DESK_WIDTH - FRAME, STRUT_DEPTH);
+                }
+            }
+        }
+    }
+}
+
+// layer 3
+translate([0, 0, layer_y(3)]){
+
+    // the actually usable deskTOP
+    board(DESK_WIDTH, DESK_DEPTH - STAND_DEPTH_INNER - DESK_TOP_OFFSET);
+    
+    // small left/right frame pieces to make sandwhich sides seamless (i.e. no holes in vertical space)
+    translate([0, DESK_DEPTH - STAND_DEPTH_INNER - DESK_TOP_OFFSET]){
+        color("orange"){
+            board(FRAME, STAND_DEPTH_INNER + DESK_TOP_OFFSET);
+            translate([DESK_WIDTH - FRAME, 0]){
+                board(FRAME, STAND_DEPTH_INNER + DESK_TOP_OFFSET);
+            }
+        }
+    }
+}
+
+// stand, only if LAYER_SPACE is 0
+if (LAYER_SPACE == 0) {
+
+    translate([0, DESK_DEPTH - STAND_DEPTH_INNER]){
+
+        // stand top piece
+        translate([-BOARD_THICKNESS, 0, SANDWICH_HEIGHT + STAND_ABOVE_SANDWICH]){
+            board(STAND_WIDTH, STAND_DEPTH_OUTER);
+        }
+
+        // tray top supports
+        translate([0, 0, SANDWICH_HEIGHT]){
+            color("orange"){
+
+                translate([FRAME - BOARD_THICKNESS, 0]){
+                    board_side(STAND_DEPTH_INNER, STAND_ABOVE_SANDWICH);
+                }
+
+                translate([DESK_WIDTH - FRAME, 0]){
+                    board_side(STAND_DEPTH_INNER, STAND_ABOVE_SANDWICH);
+                }
+            }
+        }
+
+        // stand backplate
+        translate([-BOARD_THICKNESS, STAND_DEPTH_INNER, -STAND_BELOW_SANDWICH + BOARD_THICKNESS]){
+            board_back(STAND_WIDTH, STAND_HEIGHT_INNER);
+        }
+
+        // alignment for bottom of stand
+        translate([0, 0, -STAND_BELOW_SANDWICH]){
+
+            // stand bottom piece
+            translate([-BOARD_THICKNESS, 0]){
+                board(STAND_WIDTH, STAND_DEPTH_OUTER);
+            }
+
+            translate([0, 0, BOARD_THICKNESS]){
+                // stand sidepieces
+                translate([-BOARD_THICKNESS, 0]){
+                    board_side(STAND_DEPTH_INNER, STAND_HEIGHT_INNER);
+                }
+
+                translate([DESK_WIDTH, 0]){
+                    board_side(STAND_DEPTH_INNER, STAND_HEIGHT_INNER);
+                }
+            
+                // main support, triangular
+                color("red"){
+                    translate([DESK_WIDTH / 2, STAND_DEPTH_INNER - MAIN_SUPPORT_DEPTH]){
+
+                        // left
+                        translate([-BOARD_THICKNESS, 0]){
+                            board_side(MAIN_SUPPORT_DEPTH, STAND_BELOW_SANDWICH);
+                        }
+
+                        board_side(MAIN_SUPPORT_DEPTH, STAND_BELOW_SANDWICH);
+                    }
+                }
+            }
+
+        }
+
+        // aligned to surface of tray
+        translate([0, 0, - ( STAND_BOTTOM_RACKUNITS * RACKUNIT )]){
+
+            // tray bottom
+            translate([0, 0, -BOARD_THICKNESS]){
+                board(DESK_WIDTH, STAND_DEPTH_INNER);
+            }
+
+            // tray bottom supports (vertical stress transfer for backside of frame
+            color("orange"){
+
+                translate([FRAME - BOARD_THICKNESS, 0]){
+                    board_side(STAND_DEPTH_INNER, (STAND_BOTTOM_RACKUNITS * RACKUNIT));
+                }
+
+                translate([DESK_WIDTH - FRAME, 0]){
+                    board_side(STAND_DEPTH_INNER, (STAND_BOTTOM_RACKUNITS * RACKUNIT));
+                }
+
+            }
+        
+            // tray 10" montage piece left
+            translate([FRAME + 254, 0]){
+                board_side(STAND_DEPTH_INNER, (STAND_TOP_RACKUNITS * RACKUNIT) + SANDWICH_HEIGHT + (STAND_BOTTOM_RACKUNITS * RACKUNIT));
+            }
+
+            // tray 10" montage piece right
+            translate([DESK_WIDTH - BOARD_THICKNESS - FRAME - 254, 0]){
+                board_side(STAND_DEPTH_INNER, (STAND_TOP_RACKUNITS * RACKUNIT) + SANDWICH_HEIGHT + (STAND_BOTTOM_RACKUNITS * RACKUNIT));
+            }
+        }
+    }
+}

modules.scad

@@ -14,6 +14,43 @@ module leg(height) {
     }
 }
 
+module backplate(width) {
+    difference() {
+        // main plate
+        color(COLORSCHEME == "semantic" ? COLOR_SEMANTIC_LOAD_BEARING : COLOR_WOOD) {
+            cube([width, _BACKPLATE_HEIGHT, BACKPLATE_THICKNESS]);
+        }
+
+        translate([
+            -CUTOUT_OVERCOMMIT,
+            _BACKPLATE_HEIGHT - FRAME_THICKNESS,
+            -CUTOUT_OVERCOMMIT
+        ]){
+            color(COLOR_CUTOUT) {
+                cube([
+                    FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    FRAME_THICKNESS,
+                    CUTOUT_OVERCOMMIT + BACKPLATE_THICKNESS + CUTOUT_OVERCOMMIT]
+                );
+            }
+        }
+
+        translate([
+            MAIN_WIDTH - FRAME_MAJOR_STRUT_WIDTH,
+            _BACKPLATE_HEIGHT - FRAME_THICKNESS,
+            -CUTOUT_OVERCOMMIT
+        ]){
+            color(COLOR_CUTOUT) {
+                cube([
+                    FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    FRAME_THICKNESS,
+                    CUTOUT_OVERCOMMIT + BACKPLATE_THICKNESS + CUTOUT_OVERCOMMIT]
+                );
+            }
+        }
+    }
+}
+
 module stand_side() {
 
     difference() {
@@ -78,6 +115,80 @@ module spacer(length) {
     }
 }
 
+module frame(width, depth) {
+
+    // frame left side
+    frame_side(depth);
+
+    // frame right side
+    translate([
+        width - FRAME_MAJOR_STRUT_WIDTH,
+        0
+    ]) {
+        frame_side(depth);
+    }
+
+    frame_front(width);
+}
+
+module frame_side(depth) {
+   
+    color(COLOR_STEEL) {
+        difference () {
+            cube([FRAME_MAJOR_STRUT_WIDTH, depth, FRAME_THICKNESS]);
+
+            translate([
+                -CUTOUT_OVERCOMMIT,
+                -CUTOUT_OVERCOMMIT,
+                FRAME_THICKNESS / 2
+            ]) {
+                cube([
+                    CUTOUT_OVERCOMMIT + FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    FRAME_THICKNESS / 2 + CUTOUT_OVERCOMMIT
+                ]);
+            }
+        }
+    }
+}
+
+module frame_front(width) {
+
+    color(COLOR_WOOD){
+        difference () {
+            cube([width, FRAME_MAJOR_STRUT_WIDTH, FRAME_THICKNESS]);
+
+            // left cutout
+            translate ([
+                -CUTOUT_OVERCOMMIT,
+                -CUTOUT_OVERCOMMIT,
+                -CUTOUT_OVERCOMMIT
+
+            ]) {
+                cube([
+                    CUTOUT_OVERCOMMIT + FRAME_MAJOR_STRUT_WIDTH,
+                    CUTOUT_OVERCOMMIT + FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    CUTOUT_OVERCOMMIT + FRAME_THICKNESS / 2
+                ]);
+            }
+
+            // right cutout
+            translate ([
+                width - FRAME_MAJOR_STRUT_WIDTH,
+                -CUTOUT_OVERCOMMIT,
+                -CUTOUT_OVERCOMMIT
+
+            ]) {
+                cube([
+                    CUTOUT_OVERCOMMIT + FRAME_MAJOR_STRUT_WIDTH,
+                    CUTOUT_OVERCOMMIT + FRAME_MAJOR_STRUT_WIDTH + CUTOUT_OVERCOMMIT,
+                    CUTOUT_OVERCOMMIT + FRAME_THICKNESS / 2
+                ]);
+            }
+        }
+    }
+}
+
 // Stuff that's used for subs:
 
 module screw() {

tops/main.scad

@@ -3,10 +3,11 @@ include <../modules.scad>
 
 module top_main() {
 
+    // top plate
     translate([
         0,
         0,
-        MAIN_HEIGHT - TOP_THICKNESS
+        MAIN_HEIGHT - TOP_THICKNESS     + 1000
     ]){
         difference() {
 
@@ -32,17 +33,14 @@ module top_main() {
         }
     }
 
-    // Backplate
-    _BACKPLATE_HEIGHT = STAND_HEIGHT - STAND_THICKNESS;
+    // backplate
     translate([
         0,
         MAIN_DEPTH,
-        MAIN_HEIGHT - TOP_THICKNESS - _BACKPLATE_HEIGHT
+        _BELOW_TOP - _BACKPLATE_HEIGHT
     ]){
         rotate([90, 0, 0]){
-            color(COLORSCHEME == "semantic" ? COLOR_SEMANTIC_LOAD_BEARING : COLOR_WOOD) {
-                cube([MAIN_WIDTH, _BACKPLATE_HEIGHT, BACKPLATE_THICKNESS]);
-            }
+            backplate(MAIN_WIDTH);
         }
     }
 
@@ -50,7 +48,7 @@ module top_main() {
     translate([
         0,
         MAIN_DEPTH - BACKPLATE_THICKNESS - STAND_DEPTH,
-        MAIN_HEIGHT - TOP_THICKNESS - STAND_HEIGHT
+        _BELOW_STAND
     ]){
         color(COLORSCHEME == "semantic" ? COLOR_SEMANTIC_LOAD_BEARING : COLOR_WOOD) {
             cube([MAIN_WIDTH, STAND_DEPTH + BACKPLATE_THICKNESS, STAND_THICKNESS]);
@@ -61,7 +59,7 @@ module top_main() {
     translate([
         0,
         MAIN_DEPTH - BACKPLATE_THICKNESS - STAND_DEPTH,
-        MAIN_HEIGHT - TOP_THICKNESS - STAND_HEIGHT + STAND_THICKNESS
+        _BELOW_STAND + STAND_THICKNESS
     ]){
         rotate([90, 0, 90]){
             stand_side();
@@ -72,13 +70,22 @@ module top_main() {
     translate([
         MAIN_WIDTH - STAND_THICKNESS,
         MAIN_DEPTH - BACKPLATE_THICKNESS - STAND_DEPTH,
-        MAIN_HEIGHT - TOP_THICKNESS - STAND_HEIGHT + STAND_THICKNESS
+        _BELOW_STAND + STAND_THICKNESS
     ]){
         rotate([90, 0, 90]){
             stand_side();
         }
     }
 
+    // frame (load bearing construction under table top)
+    translate([
+        0,
+        0,
+        _BELOW_TOP - FRAME_THICKNESS
+    ]) {
+        frame(MAIN_WIDTH, MAIN_DEPTH);
+    }
+
     // cable tray
 
     // tray bottom