Dollhouse

Description

First large project I've attempted using CadQuery.
Goal was to make a modular dollhouse for my kids.

It's a tudor style house with inspiration drawn from google image searches.
The central idea is that it would be printed in roughly nine sections. With the floors and roof divided into three sections each.

I opted for the main rooms to be 175mm x 175mm x 175mm or roughly 7" x 7" x 7".
Which is about the limits of my print bed.

Code Overview

Dependencies

CadQuery - Python Cad Libary
CQ-Editor - GUI to see model changes
cadqueryhelper - Shape primitives libraries, used for object repetition. (I wrote this)
cqterrain - Primary library used to build the house (I authored this as well)

I opted for python code to make the cad model because I like making 3d models with code.
I've used OpenSCAD in the past, but it has limitations for large projects.

Pros

Python has a large ecosystem
Parts of the model can be broken up into smaller modules and tested in solation.
Version control - I can review changes to the model before committing.
Github - code is kept in the cloud in a private (or public) repo.
Re-using code from one project to the next is pretty straight forward.

Cons

Tedious, the project itself was 500+ lines of code just for the dollhouse itself.
The re-usable api was expanded out as the model was being created, which slowed down development.
If there are bugs in your logic tracking them down can be arduous, the generated models do not lend themselves well to unit tests.

In The Beginning

The initial outline of the project.
The front is too boring

Shows the breakdown of the nine sections.

Adding Exterior Details

I ended up simplifying from the initial sketch.

I used Microsoft 3d Viewer to generate the lighting on the model

Interior is still plain

Arches
Stones
Casement Windows
Lattice Windows
Roof

Arches

The arch cutouts are straight forward.

def make_arch_door(wall, length, width, height, floor_height):
    # find the bottom of the wall to align to.
    bottom = wall.faces("-Z").val()

    #create the initial shape
    cutout = (cq.Workplane(bottom.Center())
              .box(length, width, height)
              .translate((0,0,(height/2)+floor_height))
              )

    # round off the top          
    cutout = cutout.faces("Z").edges("Y").fillet((length/2)-.5)

    #remove the arch from the wall
    w = wall.cut(cutout)
    return w

The arch is aligned to the bottom of the object it's being cut out of.

Stones

I opted, to write a pseudo-random stone pattern generator

Code for a stone section.

def add_stones(wall, length, height, wall_width, rotate=0, seed="test4"):
    # static boxes to act as stone
    tile = cq.Workplane("XY").box(10,10,2)
    tile2 = cq.Workplane("XY").box(8,8,2)
    tile3 = cq.Workplane("XY").box(6,12,2)

    # create an array of the stones and chamfer / fillet to add interest to the shapes.
    stone_list = [tile.chamfer(0.8), tile2.fillet(.5), tile3.chamfer(0.5)]

    # This is the pattern generator
    stones = stone.make_stones(stone_list, [12,12,2], columns = 14, rows = 3, seed=seed).rotate((0,1,0),(0,0,0), 90).rotate((0,0,1),(0,0,0), 90)

    # Align the pattern and surround with a frame
    stones = stones.translate((0,-2,-1*(height/2)+(24))).rotate((0,0,1),(0,0,0), rotate)
    frame = window.frame(length, 2, 48).translate((0,-1*((1)+(wall_width/2)),-1*(height/2)+(24))).rotate((0,0,1),(0,0,0), rotate)

    # Add the detailing to the room wall
    return wall.add(stones).add(frame)

The generated output of the stone pattern is defined by the seed.
- different seed means different stone placement.

Let's looks at cqterrain stone.make_stones code.

import cadquery as cq
import random
import math

def make_stones(parts, dim=[5,5,2], rows=2, columns=5, seed="test4"):
    grid = cq.Assembly()
    random.seed(seed)

    # loop the rows
    for row_i in range(rows):
        row_offset = (dim[0] * row_i)
        # loop the columns per row
        for col_i in range(columns):
            col_offset = (dim[1] * col_i)

            col_push_x = 0
            col_push_y = 0
            if col_i % 2 == 1:
                col_push_x = 0
                col_push_y = 0

            z_push=0
            # move the part in a random direction along the x and y axis.
            x_rand = random.randrange(-1*(math.floor(dim[0]/2)),(math.floor(dim[0]/2)))
            y_rand = random.randrange(-1*(math.floor(dim[1]/2)),(math.floor(dim[1]/2)))

            # choose a random part from the parts list
            part_index = random.randrange(0,len(parts))

            # add the part to the assembly
            grid.add(parts[part_index], loc=cq.Location(cq.Vector(row_offset + col_push_x + x_rand, col_offset + col_push_y + y_rand, z_push)))

    length = dim[1] * columns
    width = dim[0] * rows

    # dump the assembly out as a single compound
    comp = grid.toCompound()
    work = cq.Workplane("XZ").center(0, 0).workplane()
    work.add(comp)

    # zero out the grid
    work = work.translate(((dim[0]/2),(dim[1]/2)))
    work = work.translate((-1*(width/2),-1*(length/2)))
    return work

That's all of of it, the double for loop isn't ideal but I kept it for readability.
I basically yoinked my code for laying a tile onto a grid, and modified it to support pseudo-random selection and placement.
It's not perfect but it's good enough to give the impression of a stone pattern.
The code isn't resource intensive since it's made up of very simple primitives.

Casement Windows

Code for making the windows.

def casement_windows(wall, length, width, height, count, padding):
    # Create the cut out the holes where the windows will be placed.
    window_cutout = cq.Workplane().box(length, width, height)
    window_cut_series = series(window_cutout, count, length_offset = padding)

    # create the window frame, and grill.
    i_window = window.frame(length, width+3, height)
    grill = window.grill(length=length, width=4, height=height, rows=4, columns=2, grill_width=2, grill_height=3)
    i_window.add(grill)

    # Create the window set
    window_series = series(i_window, count, length_offset = padding)

    # Remove the cutout and add the windows
    w = wall.cut(window_cut_series)
    w = w.add(window_series)

    return w

Making the grill.

def grill(length=20, width=4, height=40, columns=4, rows=2, grill_width=1, grill_height=1):
    # Make a flat plane
    pane = cq.Workplane("XY").box(length, grill_height, height)
    t_width = length / columns
    t_height = height / rows

    # Make the window cutout
    tile = cq.Workplane("XY").box(t_width, grill_height, t_height).rotate((1,0,0),(0,0,0),90)

    # Repeat the cutout
    tiles = grid.make_grid(tile, [t_width+grill_width, t_height+grill_width], rows=columns, columns=rows).rotate((1,0,0),(0,0,0),-90)

    # Remove the window cutouts leaving the frame
    combine = pane.cut(tiles)
    return combine

The tudor framing on the outside of the house are just these casement window grills.

Lattice Windows

The only difference between the casement and the lattice is the grill pattern.

def lattice(length=20, width=4, height=40,  tile_size=4, lattice_width=1, lattice_height=1, lattice_angle=45):
    # Determine longest distance between points
    hyp = math.hypot(length, height)
    columns= math.floor(hyp / (tile_size+lattice_width))
    rows= math.floor(hyp / (tile_size+lattice_width))

    # Make a flat plane
    pane = cq.Workplane("XY").box(length, lattice_height, height)

    #make the cutout tile
    tile = cq.Workplane("XY").box(tile_size, lattice_height, tile_size).rotate((1,0,0),(0,0,0),90)
    tiles = grid.make_grid(tile, [tile_size+lattice_width, tile_size+lattice_width], rows=columns, columns=rows).rotate((1,0,0),(0,0,0),-90).rotate((0,1,0),(0,0,0),lattice_angle)
    combine = pane.cut(tiles)
    return combine

Roof

The roof tiles were a struggle but it was a good opportunity re-learn some trigonometry.

Code to make a roof.

def make_roof(roof_width=185, x_offset=0):
    # Make the wedge shape
    gable_roof_raw = roof.dollhouse_gable(length=roof_width, width=185, height=100)

    # Shell the roof to cut out the inside
    gable_roof = roof.shell(gable_roof_raw,face="Y", width=-4)

    # Determine the arccosine angle of the roof
    angle = roof.angle(185, 100)
    face_x = gable_roof_raw.faces("<X")

    # Feature to enable/disable rendering roof tiles
    if render_roof_tiles:
        # Individual roof tile
        tile = cq.Workplane("XY").box(15,12,2).rotate((0,1,0),(0,0,0),8)
        # Grid of tiles
        tiles = roof.tiles(tile, face_x, 185, 100, 15, 12, angle, rows=28, odd_col_push=[3,0], intersect=False).rotate((0,0,1),(0,0,0),90).translate((3,45,0))
        tiles = tiles.translate((x_offset,0,0))

        # Cut away box to remove excess tiles
        inter_tiles = cq.Workplane("XY").box(roof_width,185, 100)
        inter_tiles = tiles.intersect(inter_tiles)
        return gable_roof.add(inter_tiles)
    else:
        # Quick roof no tiles
        return gable_roof

Making the tiles is resource intensive, so a feature flag was added for quick rendering.

Making the wedge

def dollhouse_gable(length= 40, width=40, height=40):
    roof = cq.Workplane("XY" ).wedge(length,height,width,0,0,length,0).rotate((1,0,0), (0,0,0), -90)
    return roof

Shell the roof

def shell(part, face="-Z", width=-1):
    result = part.faces(face).shell(width)
    return result

Determine angle

def angle(length, height):
    '''
    Presumed length and height are part of a right triangle
    '''
    hyp = math.hypot(length, height)
    angle = length/hyp
    angle_radians = math.acos((angle))
    angle_deg = math.degrees(angle_radians)
    return angle_deg

Additional Features

Roof Dormers
Ladder
Stairs
Floor Tiles
Clips

Roof Dormer

Implementation of the dormer

def make_dormer_roof(roof_part, width=185):
    # Wedge Used for cutout
    gable_roof_raw = roof.dollhouse_gable(length=width, width=185, height=100).translate((0,0,-4.5))

    length=185
    height = 100
    inner_height = 60

    # Sub roof of the dormer
    roof_half_one = roof.dollhouse_gable(length=140, width=40, height=30).translate((0,0,29)).rotate((0,0,1),(0,0,0),90).translate((-20,15,0))
    roof_half_two = roof.dollhouse_gable(length=140, width=40, height=30).translate((0,0,29)).rotate((0,0,1),(0,0,0),-90).translate((20,15,0))

    # Render the tiles of the dormer
    if render_roof_tiles:
        angle = roof.angle(40, 30)
        face_x = roof_half_one.faces(">X")
        tile = cq.Workplane("XY").box(15,12,2).rotate((0,1,0),(0,0,0),8)
        tiles = roof.tiles(tile, face_x, 140, 30, 15, 12, angle, rows=4, odd_col_push=[3,0], intersect=False).translate((-14.5,23,29))
        tiles2 = roof.tiles(tile, face_x, 140, 30, 15, 12, angle, rows=4, odd_col_push=[3,0], intersect=False).translate((-14.5,23,29)).rotate((0,0,1),(0,0,0),180).translate((0,46,0))

    # make the body / walls of the cut-away dormer aligned to the parent roof. combine the body of the dormer with the dormer roof
    # this one is solid
    inner = roof_part.faces("<Z").box(80,110,inner_height, combine=False).translate((0,0,inner_height/2+4))
    inner = inner.union(roof_half_one).union(roof_half_two)

    # make the body / walls of the actual dormer aligned to the parent roof. combine the body of the dormer with the dormer roof
    # this one is shelled
    inner_shell = roof_part.faces("<Z").box(80,140,inner_height, combine=False).translate((0,15,inner_height/2+4))
    inner_shell = inner_shell.union(roof_half_one).union(roof_half_two)
    inner_shell = inner_shell.faces(">Y").shell(-4)

    # cut away excess tiles
    if render_roof_tiles:
        tile_cut = cq.Workplane("XY").box(40,140,50).translate((20,15,25))
        tile_cut2 = cq.Workplane("XY").box(40,140,50).translate((-20,15,25))

        tiles = tiles.intersect(tile_cut)
        tiles2 = tiles2.intersect(tile_cut2)

        inner_shell = inner_shell.add(tiles).add(tiles2)

    # shell the dormer roof
    inner_shell = inner_shell.cut(gable_roof_raw)

    # Place the dormer onto the roof part
    combine = roof_part.cut(inner).add(inner_shell)

    # Add the window to the dormer
    window_slug = inner.faces("<Y").cylinder(8,20,combine=False).rotateAboutCenter((1,0,0),90).translate((0,2.5,10))
    window_inner = inner.faces("<Y").cylinder(8,17,combine=False).rotateAboutCenter((1,0,0),90).translate((0,2.5,10))
    win_frame = window_slug.cut(window_inner)
    grill = window.grill(40, 5, 40, 2, 2, 3, 3 ).translate((0,-52,5))
    combine = combine.cut(window_slug).add(win_frame).add(grill)

    return combine

Overall the dormer was complicated to make, and the code needs to be refactored and broken up.

Ladder

# Create a latter instance
ladder_bp = Ladder(length=30, height=175, width=8)
# Set sub-part parameters
ladder_bp.rung_padding = 12
ladder_bp.rung_height = 3
ladder_bp.rung_width = 3

# make the sub parts
ladder_bp.make()

# Combine the parts into one solid.
ladder = ladder_bp.build().rotate((0,0,1),(0,0,0),90).translate((55,-60,175))

cqterrain class - Ladder code.
Ladders are a totally different pattern.
they are class objects with two lifecycles:

make creates the sub-parts.
build assembles the parts into a solid.

Stairs

stair_lower = stairs(
length = 148,
width = 32,
height = 175,
run = 8,
stair_length_offset = 5.35,
stair_height = 3,
stair_height_offset = -.8,
rail_width = 3,
rail_height = 14,
step_overlap = None
)

Documentation
Code

Stairs are an older pattern in cqterrain, you call the constructor with parameters and it returns the solid.
The code is planned to be replaced.

Floor Tiles

The project used two variants of Floor tiles.

Octagon With Dots

Tile code

def octagon_with_dots(tile_size=5, chamfer_size = 1.2, mid_tile_size =1.6, spacing = .5 ):
    tile = (cq.Workplane("XY")
            .rect(tile_size,tile_size)
            .extrude(1)
            .edges("|Z")
            .chamfer(chamfer_size) # SET PERCENTAGE
            )

    rotated_tile = tile.rotate((0,0,1),(0,0,0), 45)

    mid_tile = (cq.Workplane("XY")
            .rect(mid_tile_size, mid_tile_size)
            .extrude(1)
            .rotate((0,0,1),(0,0,0), 45)
            )

    tiles = grid.make_grid(tile, [tile_size + spacing,tile_size + spacing], rows=3, columns=3)
    center_tiles = grid.make_grid(mid_tile, [tile_size + spacing, tile_size + spacing], rows=4, columns=4)

    combined = tiles.add(center_tiles).translate((0,0,-1*(1/2)))
    return combined

Two sets of tiles overlaid ontop of each other.
When a tile is applied to a room; the code is built to know what to do with that.

  bp.floors[0].floor_tile = tile.octagon_with_dots(10, 2.4, 3.2, 1)
  bp.floors[0].floor_tile_padding = 1
  bp.floors[0].make()

Basketweave

def basketweave(length = 4, width = 2, height = 1, padding = .5):
    length_padding = length + padding
    width_padding = width + padding
    rect = (
            cq.Workplane("XY")
            .box(width, length_padding, height)
            .center(width_padding, 0)
            .box(width, length_padding, height)
            .translate((-1*(width_padding/2), 0, 0))
            )

    rect2 = (
            cq.Workplane("XY")
            .box(width, length_padding, height)
            .center(width_padding, 0)
            .box(width, length_padding, height)
            .translate((-1*(width_padding/2), 0, 0))
            .rotate((0,0,1), (0,0,0), 90)
            .translate((width_padding*2, 0, 0))
        )

    combine = (cq.Workplane("XY").union(rect).union(rect2).translate((-1*(width_padding),0,0)))
    combine2 = (cq.Workplane("XY")
                .union(combine)
                .rotate((0,0,1),(0,0,0), 180)
                .translate((0,width_padding*2,0))
                )

    tile_combine = cq.Workplane("XY").union(combine).union(combine2).translate((0,-1*(width_padding),0))
    return tile_combine

Clips

I ended up making a couple clip variants to hold the parts together.

Clip code

import cadquery as cq

def clip():
    part1 = cq.Workplane("XY").box(12.5, 24, 8)
    inner = cq.Workplane("XY").box(8.5,22,8).translate((0,-1,0))
    combined = part1.cut(inner)
    combined = combined.fillet(.3)
    return combined

part_clip = clip()
show_object(part_clip)

The clips work so-so.

Printing

On average each part takes about 2 days to print.
I spent 3 weeks printings parts.
No Support materials were needed for any of the parts.
The part modularity was a plus, and allows the kids to re-organize the house into different shapes or multiple smaller houses.
If I were to do this again I would add a more robust mechanism for connecting parts together.

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README.md

README.md

Dollhouse

Description

Code Overview

Dependencies

Pros

Cons

In The Beginning

Adding Exterior Details

Arches

Stones

Casement Windows

Lattice Windows

Roof

Additional Features

Roof Dormer

Ladder

Stairs

Floor Tiles

Octagon With Dots

Basketweave

Clips

Printing

Files

README.md

Latest commit

History

README.md

File metadata and controls

Dollhouse

Description

Code Overview

Dependencies

Pros

Cons

In The Beginning

Adding Exterior Details

Arches

Stones

Casement Windows

Lattice Windows

Roof

Additional Features

Roof Dormer

Ladder

Stairs

Floor Tiles

Octagon With Dots

Basketweave

Clips

Printing