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Fix pill-shaped screw hole CSG export issue

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Add epsilon offsets to pill hole geometry to prevent coplanar face
issues during STL/3MF export. F6 render was correct but mesh export
was dropping the recesses due to CGAL handling of coincident surfaces.

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>
This commit is contained in:
Cal Corum 2025-12-24 15:02:28 -06:00
parent de88c8b794
commit a243e9a1f9
2 changed files with 10 additions and 6 deletions
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8
light-switches/gfci-paddle-switch-extended-offset.scad
View File

@ -107,16 +107,18 @@ module paddle_opening_3d() {
module screw_holes() {
if (screw_holes_enabled) {
// Main screw holes: recessed from back face (positive Z), solid wall on front
main_screw_start_z = plate_thickness - main_screw_recess_depth;
// Start slightly below target to ensure clean CSG intersection
main_screw_start_z = plate_thickness - main_screw_recess_depth - 0.01;
main_screw_cut_height = plate_thickness - main_screw_start_z + 0.1;
// Top main screw hole (pill-shaped, horizontal)
translate([0, screw_hole_spacing/2, main_screw_start_z])
linear_extrude(height = main_screw_recess_depth + 0.1)
linear_extrude(height = main_screw_cut_height)
rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
// Bottom main screw hole (pill-shaped, horizontal)
translate([0, -screw_hole_spacing/2, main_screw_start_z])
linear_extrude(height = main_screw_recess_depth + 0.1)
linear_extrude(height = main_screw_cut_height)
rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
}

8
light-switches/gfci-paddle-switch-extended.scad
View File

@ -101,16 +101,18 @@ module paddle_opening_3d() {
module screw_holes() {
if (screw_holes_enabled) {
// Main screw holes: recessed from back face (positive Z), solid wall on front
main_screw_start_z = plate_thickness - main_screw_recess_depth;
// Start slightly below target to ensure clean CSG intersection
main_screw_start_z = plate_thickness - main_screw_recess_depth - 0.01;
main_screw_cut_height = plate_thickness - main_screw_start_z + 0.1;
// Top main screw hole (pill-shaped, horizontal)
translate([0, screw_hole_spacing/2, main_screw_start_z])
linear_extrude(height = main_screw_recess_depth + 0.1)
linear_extrude(height = main_screw_cut_height)
rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
// Bottom main screw hole (pill-shaped, horizontal)
translate([0, -screw_hole_spacing/2, main_screw_start_z])
linear_extrude(height = main_screw_recess_depth + 0.1)
linear_extrude(height = main_screw_cut_height)
rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
}