openUC2 CadQuery Insert Generator (v4-style)

Programmatic generation of an openUC2 cube insert and component cutouts using CadQuery.

Python-generated generic insert that can e.g. host a lens or something

Goal:

• Create a reusable insert “blank” (outer geometry + optional tabs/wings + threaded holes).
• Create separate component STEP cutters (lens pockets, motor clearances, etc.).
• Import any STEP cutter, apply an affine transform, and subtract it from the insert to produce a printable/custom holder.

Coordinate system:

• Optical axis = Z-axis
• Optical axis passes through (0, 0) in the XY-plane
• All shapes are built around the origin by default

Files

1) uc2_component_cut_step.py

Creates a negative volume (“cutter”) as a STEP file.

Typical use:

• Generate a lens pocket as a cylinder + optional seat + optional set-screw holes.
• Export as component_cut.step (and optionally component_cut.stl).

You can create multiple cutters, e.g.:

• lens_25mm_cut.step
• motor_clearance_cut.step
• laser_mount_cut.step

These STEP cutters are then consumed by the insert builder.

2) uc2_insert_builder.py

Creates the insert body and subtracts one or more imported STEP cutters.

What it generates:

• Outer insert outline (octagon-like profile from the technical drawing)
• Optional side tabs (or “wings” depending on the version you use)
• Optional center bore (or you do center bore via cutter STEP)
• Optional threaded/tapping holes
• Subtraction of imported cutters after applying affine transforms
• Exports uc2_insert.step and uc2_insert.stl

Install

Create an environment and install CadQuery:

pip install cadquery

If your Python environment is already set up (e.g. mambaforge), install into that environment.

Quick start

Step 1: Create a cutter STEP (example lens pocket)

python uc2_component_cut_step.py

This writes:

• component_cut.step
• component_cut.stl (optional)

Step 2: Build the insert and subtract the cutter

Edit uc2_insert_builder.py and add the cutter to CUTTERS, then run:

python uc2_insert_builder.py

This writes:

• uc2_insert.step
• uc2_insert.stl

How cutters work

A cutter is any solid STEP you want to subtract from the insert.

Typical workflow:

1. Generate a cutter STEP in a dedicated script (preferred, reproducible)
2. Add it to CUTTERS list in uc2_insert_builder.py
3. Assign an affine transform for positioning/orientation
4. Boolean subtract (insert.cut(cutter))

This supports:

• Lens holders (coaxial to optical axis)
• Motor pockets (offset + rotated)
• LED/laser holders
• Cable channels / clearance volumes
• Any imported CAD STEP solid

Affine transforms

Each cutter can be positioned and rotated with:

• Translation: tx, ty, tz (mm)
• Rotation: rx, ry, rz (degrees, applied about origin, in order X → Y → Z)

Example: shift 2 mm in X, rotate 15° around optical axis:

CUTTERS = [
    ("component_cut.step", Affine(tx=2.0, ty=0.0, tz=0.0, rx=0.0, ry=0.0, rz=15.0)),
]

Tip:

• If you want a lens centered on the optical axis, keep (tx, ty) = (0, 0).

Parameters you typically adjust

In uc2_insert_builder.py:

• OUTER_HALF, SHOULDER_HALF : insert outline
• INSERT_THICKNESS : extrusion thickness
• ADD_SIDE_TABS, tab dimensions
• ADD_THREAD_HOLES and hole geometry
• CUTTERS list and each cutter transform

In uc2_component_cut_step.py:

• Lens diameter + clearance
• Seat diameter + depth
• Set screw count, diameter, radius

License / contributions

This approach is meant to support openUC2’s open insert ecosystem:

• Generate inserts reproducibly
• Share scripts + parameters
• Allow others to remix and extend

If you create a useful cutter for a common component (lens size, motor, LED), publish it with:

• source script
• generated STEP
• a short usage snippet (recommended transform and parameters)