Parametrical Wooden Plug arrangement for Model Slits

I created an OpenSCAD skript to define a number of bolts (wooden plugs) in a circular arrangement.

Those I use in my large robot figures for splitting the model and making assembly way more simple.

I scale up my model to the desired size. Afterwards I load a group of bolts as negative volume into the model before actually cutting it. That way I can use standard wooden plugs from any hardware store to help to align the parts while assembling them. The plugs also provide additional strength to the glued surfaces. 

The OpenSCAD file can be used with parameters. You simply define

• Length of one plug
• Diameter of one plug
• Number of plugs you want to have in your circular arrangement
• Radius of the circular arrangement (center of the plugs)

Then you get an STL file contining this arrangement and use it as negative volume in your model before splitting it.

Of course you also can print the plugs instead of buying wooden ones … So you can make use of your small filament leftovers. Depending on the accuracy of your printer (and Filament) you have to print the plugs slightly smaller than the negative volume.

Also the tolerances of the bought wooden plugs are far away from perfect :) … So those are the numbers that work out great for me:

• Diameter of the plugs +0.4mm in regard to the plug diameter
• Length I use exactly the length of the bolts since I added spheres at the end of the volumes which cover the tolerances there easily

When printing the plugs I use the standard size (-0.4mm compared to the negative volume) and also print them 2mm short since they also contain the speres on either end.

I am using this script quite some time now … but never published it because I considered it too simple. But since they are such a good help when combining parts of split models … I am pretty sure other makers have similar issues as well.