adding a new honeycomb tray based on angle-bracket

rack-mount/catalog/honeycomb-tray/README.md

@@ -0,0 +1,16 @@
+
+# Angle Bracket System
+
+
+![demo](./animate.gif)
+
+Please see [honeycomb.scad](./honeycomb.scad) for config and building. Make sure the correct rack profile is configured in [rackFrame.scad](../../config/rackFrame.scad).
+
+This uses the [angle brackets](./entry.scad) for the sides, but creates a full honeycomb tray spanning boxWidth and boxDepth for more stability, ventilation and less print material.
+
+### BOM:
+
+| Item                                                          | Name                      | Quantity | Comment                                                                                                                          |
+|---------------------------------------------------------------|---------------------------|----------|----------------------------------------------------------------------------------------------------------------------------------|
+| <img src="../../media/bom/fhcs_medium.gif"  height="60" width="72"> | M3x12 FHCS                | 8        | Extras are useful and inexpensive. If you plan on eventually stacking multiple racks together, don't hesitate to get a lot more. |
+| <img src="../../media/bom/hex_nut.gif"  height="60" width="72">     | M3 hex nut                | 8        | ☝️                                                                                                                               |

rack-mount/catalog/honeycomb-tray/animate.scad

@@ -0,0 +1,24 @@
+use <./entry.scad>
+
+$vpt = [120,-30,63];
+$vpr = [74,0,25];
+$vpd = 550;
+$vpf = 22.50;
+
+animateAngleBrackets(at=$t);
+
+
+module animateAngleBrackets(at=$t) {
+
+    x = 150;
+    y = 70;
+    dx = abs(lerp(a=-20, b=20, t=at));    
+    dy = abs(lerp(a=-50, b=50, t=at));
+
+    u = abs(at - 0.5) > 0.25 ? 3 : 4;
+
+    angleBrackets(visualize=true, boxWidth=x+dx, boxDepth=y+dy, u=u);
+
+}
+
+

rack-mount/catalog/honeycomb-tray/entry.scad

@@ -0,0 +1,36 @@
+include <../common.scad>
+
+use <../enclosed-box/sideRail.scad>
+
+
+/*
+  Simple angle bracket mounting system. Mainly derived the enclosed box system. 
+*/
+module angleBrackets (
+    // begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
+
+    // Does not affect any part dimensions. Set this to true to visualize how a box would be mounted.
+    visualize = false,
+
+
+    thickness = 1,
+    boxWidth = 203,
+    boxDepth = 145,
+    sideVent = true,
+    u = 3
+
+    // end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
+) {    
+
+    sideSupportRailBase(top=false, defaultThickness=thickness, railSideThickness=thickness, supportedZ=10*u-2*thickness, supportedY=boxDepth, supportedX=boxWidth, sideVent=sideVent);
+
+    rightRailTrans = visualize
+        ? translate(v=[boxWidth,0,0]) * mirror(v=[1,0,0])
+        : translate(v=[30,0,0]) * mirror(v=[1,0,0]);
+
+    multmatrix(rightRailTrans)
+    sideSupportRailBase(top=false, defaultThickness=thickness, railSideThickness=thickness, supportedZ=10*u-2*thickness, supportedY=boxDepth, supportedX=boxWidth, sideVent=sideVent);
+}
+
+
+angleBrackets();

rack-mount/catalog/honeycomb-tray/honeycomb.scad

@@ -0,0 +1,108 @@
+
+// ===== Combined Assembly (Fixed): Entry Brackets + Honeycomb Tray =====
+// - Uses your exact bracket geometry from entry.scad
+// - Places right bracket using visualize=true so spacing = boxWidth
+// - Honeycomb subtraction fixed: keeps walls, removes hex cores
+//
+// Keep your project structure so `use <entry.scad>` resolves correctly.
+use <entry.scad>;
+
+// ---------------- User Parameters ----------------
+boxWidth        = 203;
+boxDepth        = 145;
+base_thickness  = 3.0;   // tray plate thickness
+wall_thickness  = 1.0;   // forwarded to entry.scad's thickness
+u               = 4;
+sideVent        = true;
+
+// Honeycomb
+hex_side   = 6.0;
+cell_wall  = 1.5;
+rim_width  = 3.0;
+
+// Vertical and bonding tweaks
+baseZ      = -1.0;     // Z of tray (align with rail bottoms, -1.0 puts it on print bed)
+bondOverlapX = 3.0;   // extend tray under rails in X (each side)
+bondOverlapY = 0.0;   // extend slightly front/back in Y if desired
+
+// ---------------- Honeycomb Helpers ----------------
+module __hex2d(side) {
+    polygon(points=[ for (i=[0:5]) [ side*cos(60*i), side*sin(60*i) ] ]);
+}
+
+module __honeycomb_plate(width, depth, plate_h, side, wall, rim) {
+    // Full plate, then subtract ONLY the inner hex cores inside the rim area.
+    difference() {
+        cube([width, depth, plate_h], center=false);
+
+        // Subtract hex cores
+        x_step = 1.5 * side;
+        y_step = sqrt(3) * side;
+        w = width  - 2*rim;
+        d = depth  - 2*rim;
+
+        translate([rim, rim, 0])
+        union() {
+            for (ix = [0 : ceil(w / x_step) + 1]) {
+                x = side + ix * x_step;
+                y_off = (ix % 2) * (y_step/2);
+                for (iy = [0 : ceil(d / y_step) + 1]) {
+                    y = y_off + iy * y_step;
+                    if (x >= 0 && x <= w && y >= 0 && y <= d) {
+                        // subtract inner hex only -> leaves walls
+                        translate([x, y, 0])
+                            linear_extrude(height=plate_h + 0.05)
+                                __hex2d(max(0.01, side - wall));
+                    }
+                }
+            }
+        }
+    }
+}
+
+// ---------------- Bridge to your entry.scad ----------------
+module __entry_brackets(
+    wall_t = wall_thickness,
+    width  = boxWidth,
+    depth  = boxDepth,
+    unit   = u,
+    vent   = sideVent
+) {
+    // visualize=true so right rail is placed at x=boxWidth
+    angleBrackets(
+        visualize = true,
+        thickness = wall_t,
+        boxWidth  = width,
+        boxDepth  = depth,
+        u         = unit,
+        sideVent  = vent
+    );
+}
+
+// ---------------- Final Assembly ----------------
+module angleBrackets_with_honeycomb_tray(
+    width        = boxWidth,
+    depth        = boxDepth,
+    base_h       = base_thickness,
+    wall_t       = wall_thickness,
+    unit         = u,
+    vent         = sideVent,
+    hex_side_in  = hex_side,
+    cell_wall_in = cell_wall,
+    rim_in       = rim_width,
+    baseZ_in     = baseZ,
+    bondOX       = bondOverlapX,
+    bondOY       = bondOverlapY
+) {
+    union() {
+        // 1) Brackets from your entry.scad
+        __entry_brackets(wall_t=wall_t, width=width, depth=depth, unit=unit, vent=vent);
+
+        // 2) Tray centered between x=[0,width] and y=[0,depth], with small overlap under rails
+        translate([-bondOX, -bondOY, baseZ_in])
+            __honeycomb_plate(width + 2*bondOX, depth + 2*bondOY, base_h, hex_side_in, cell_wall_in, rim_in);
+    }
+}
+
+// Preview
+angleBrackets_with_honeycomb_tray();