🧱 Modular Blade Assembly

"Lego Block" Design with T-Wedge Connectors
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Concept Overview

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

Key Components

ComponentColor (CAD)Description
Blade SegmentsWhite/GraySteel plate sections forming blade body
Overlap ZonesGray (2× thick)Where segments overlap by 2× material thickness
T-Wedge ConnectorsCyanDrop-in from ÂąZ to lock overlapping segments
Spring ClipsCyanSnap-in from side as alternative to T-wedge
FeetGrayOptional extensions that drop into baseplate slots
BaseplateBrownBase with pre-cut slots at blade foot locations

📐 Reference CAD Model

View Full SVG Diagram →

Modular Blade CAD

Assembly Rules

  • ✓ Segments overlap by 2× material thickness at joints
  • ✓ T-Wedge drops in from above/below (ÂąZ) to lock segments
  • ✓ Spring Clip snaps in from side as alternative
  • ✓ Cross-blades ONLY slot through single-layer zones (not overlaps)
  • ✓ Blades connect to baseplate via T-slots + T-wedges
  • ✓ Supports compound angles between segments

⚠️ Cross-Blade Rule

Cross-blades can ONLY slot through single-layer zones, NOT overlap zones. This ensures structural integrity of the connection.

Connection Types

T-Wedge Connectors

T-WEDGE CONNECTION (Cross-section) Segment A Segment B ┌─────────┐ ┌─────────┐ │ │ │ │ │ ┌────┴─────────┴────┐ │ │ │ T-WEDGE │ │ ◀── Drops in from top │ │ ┌─────┐ │ │ │ └────┤ ├────────┘ │ │ │ │ │ └─────────┴─────┴─────────────┘ OVERLAP ZONE

Spring Clips

Alternative to T-wedge - snaps in from the side for easier assembly in tight spaces.

Laminated Blade Connections - Offset Plug Weld

For laminated blades (multiple stacked layers), use staggered hole patterns for sequential plug welding from top only.

Benefits

BenefitDescription
✓ Incrementally buildableAdd segments as needed
✓ Easily removableRework without destroying fixture
✓ No welding requiredPurely mechanical assembly
✓ Reusable componentsSegments can be repurposed
✓ Compound angle supportComplex fixture geometries
✓ Modular like LegoStandardized connections

Implementation Status

  • ○ 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 (T-wedge/clip counts)
  • ○ sma 2417 - Simplify topology after booleans

📦 Deliverables

fxModularBladeAssembly.ovm - segment connection logic

fxTWedgeGenerator.ovm - T-wedge slot cutting

fxSpringClipSlot.ovm - spring clip aperture generation

fxLaminatedHolePattern.ovm - offset hole positions per layer