🛠️ Blade Profile & Modular Assembly

🛠️ Blade Profile Dual-Mode Architecture

Two complementary approaches for blade profile generation, preserving existing work while adding a faster alternative.

Mode A: Precise Section (Current - 2026)

Input: Part solid + blade plane at compound angle │ └─▶ sld sec (solid/plane intersection) │ └─▶ Extract intersection curves │ └─▶ Validate + build kurves │ └─▶ Output: Exact contact profile Pros: Accurate contact points, compound angle support Cons: Slower (~64s for 6 tests), requires watertight prep Use: Complex parts, angled blades, precision fixtures

Mode B: Fast Projection (Legacy - 2019)

Input: Part solid + blade line position │ └─▶ Create full-height blade solid │ └─▶ For each face: extrude in Z direction │ └─▶ Subtract extruded faces from blade │ └─▶ Rotate flat, convert to kurves │ └─▶ Output: Projected silhouette profile Pros: Much faster, handles overhangs naturally Cons: Z-only direction, less precise on curves Use: Simple parts, quick prototyping, bulk processing

Hybrid Strategy (Planned)

BLADE_PROFILE = UNION( sld_sec_intersection, ← Accurate contact (Mode A) projected_bbox_silhouette ← Full coverage (Mode B concept) ) Ensures blades extend to support overhanging geometry while maintaining precise contact point accuracy.

⚠️ Implementation Note

Do NOT modify existing Mode A (fxBladeProfileVector, fxProfileToKurve3D, compound macros). Mode B will be a separate code path selected via parameter. Both modes output compatible kurve formats.

📦 Files

Mode A (Preserve): fxBladeProfileVector.ovm, fxProfileToKurve3D.ovm, fxxProfileToKurve3D_Compound.ovm

Mode B (Resurrect): fxComputeBladeEdge2019.ovm, fxExtrudeSolidForBladeEdge.ovm

Reference: session-results-2026-01-02.html - performance metrics

🧱 Modular Blade Assembly System ("Lego Block" Design)

🔗 Concept Overview

A modular approach to blade construction where blades are built from segmented pieces that connect together using T-wedges or spring clips. Blades stand vertically on a baseplate with pre-cut slots. This enables incremental assembly, easy rework, and reusable components without welding.

📐 Reference CAD Model

4-view layout showing the modular assembly concept:

📊 SVG Diagram

View Full SVG Diagram →

🔧 Key Components

Component	Color (CAD)	Description
Blade Segments	White/Gray	Steel plate sections that form the blade body
Overlap Zones	Gray (2× thick)	Where segments overlap by 2× material thickness
T-Wedge Connectors	Cyan	Drop-in from ±Z to lock overlapping segments
Spring Clips	Cyan	Snap-in from side as alternative to T-wedge
Feet	Gray	Optional blade extensions that drop into baseplate slots (not required on every segment)
Baseplate	Brown/Copper	Base with pre-cut slots at blade foot locations

📏 Assembly Rules

Segments overlap by 2× material thickness at joints
T-Wedge drops in from above/below (±Z) to lock segments together
Spring Clip snaps in from side as alternative locking method
Cross-blades can ONLY slot through single-layer zones (not overlap zones)
Blades connect to baseplate via T-slots + T-wedges (feet optional per segment)
Supports compound angles between segments

✅ Benefits

✓ Incrementally buildable
✓ Easily removable for rework
✓ No welding required for assembly

✓ Reusable components
✓ Compound angle support
✓ Modular like Lego blocks

📦 TODO - Implementation

○ Define standard T-wedge and spring clip dimensions
○ Implement overlap zone detection at segment joints
○ Auto-place connection holes in overlap zones
○ Cross-blade intersection validation (single-layer only)
○ Baseplate T-slot generation for blade mounting
○ BOM generation for connectors (T-wedge/clip counts)
○ sma 2417 - Simplify topology after boolean operations

Files:

fxModularBladeAssembly.ovm - segment connection logic

fxTWedgeGenerator.ovm - T-wedge slot cutting

fxSpringClipSlot.ovm - spring clip aperture generation