Underware OpenSCAD Code Generation

Generates OpenSCAD code for parametric cable management channels compatible with OpenGrid/Multiboard wall-mounted systems.

Required Reading Before Generating Code

Authoritative source (fetch every time):

• QuackWorks Underware Repository: https://github.com/AndyLevesque/QuackWorks/tree/main/Underware
  • Reference implementation for all channel types
  • Licensed CC BY-NC-SA 4.0
  • Active development with bug fixes and enhancements

Local reference clone (if GitHub unavailable):

• /Users/aaron/workspace/infra/neat-little-package/.tmp/QuackWorks/Underware/*.scad

Related documentation:

• Hands on Katie guide: https://handsonkatie.com/underware-2-0-the-made-to-measure-collection/
• OpenGrid integration: See home-organization/SKILL.md for system compatibility

Core Understanding (Critical Architecture)

What Makes Underware Different From Generic Cable Channels

Two-part snap system: Every channel consists of separate Base + Top pieces:

• Base: Mounts to wall/surface with various mounting methods
• Top: Clips onto base, removable for cable access
• Snap profile: Precision-engineered interlock (~3mm overlap)
• Why this matters: User can route cables, snap on tops, remove tops later without unmounting

Path-sweep construction: All channels use BOSL2 path_sweep() for complex geometries:

// Profile defines cross-section shape
// Turtle commands define path through space
path_sweep(baseProfile(widthMM = 25), turtle(["move", lengthMM]))

Profile scaling for width: Multi-unit channels expand by stretching center rectangle:

// 1-unit channel: 25mm wide (standard profile)
// 2-unit channel: 50mm wide (profile halves moved apart, rectangle fills gap)
function baseProfile(widthMM = 25) =
    union(
        left((widthMM-25)/2, selectBaseProfile),  // Left half
        right((widthMM-25)/2, mirror([1,0], selectBaseProfile)),  // Right half mirrored
        back(3.5/2, rect([widthMM-25+0.02, 3.5]))  // Center fill rectangle
    );

Grid-based dimensioning: All dimensions in 25mm grid units (OpenGrid/Multiboard standard):

• Grid_Size = 25 (constant, do not modify)
• Channel_Width_in_Units = 1 → 25mm wide channel
• Channel_Length_Units = 5 → 125mm long straight channel

BOSL2 Dependencies (Required)

All channel files require:

include <BOSL2/std.scad>
include <BOSL2/rounding.scad>
include <BOSL2/threading.scad>

Why these specific libraries:

• std.scad: Core geometry operations (path_sweep, turtle, attachable)
• rounding.scad: Smooth corners on profiles
• threading.scad: Threaded snap connector generation

Channel Type Selection Framework (Decision Layer)

By Cable Routing Need

Routing Need	Channel Type	Key File	Read Subpage
Straight run with cord exits	I Channel	Underware_I_Channel.scad	./straight-runs.md
90° corner, independent arm lengths	L Channel	Underware_L_Channel.scad	./corners-junctions.md
3-way intersection	T Channel	Underware_T_Channel.scad	./corners-junctions.md
4-way cross	X Channel	Underware_X_Channel.scad	./corners-junctions.md
Split one path to two	Y Channel (Branch Split)	Underware_Branch_Split_Channel.scad	./corners-junctions.md
Smooth diagonal transition	S Channel	Underware_S_Channel.scad	./curves-transitions.md
Quarter/half/full circle	C Channel	Underware_C_Channel.scad	./curves-transitions.md
45° angled corner	Mitre Channel	Underware_Mitre_Channel.scad	./curves-transitions.md
Vertical level change	Height Change Channel	Underware_Height_Change_Channel.scad	./curves-transitions.md

By Use Case Examples

User wants to	Recommended approach	Notes
Route desk power cables horizontally	I Channel with cord cutouts	Use Both Sides cutouts for multiple exit points
Turn corner around desk edge	L Channel	Set L_Channel_Length_in_Units_Y/X_Axis independently
Create cable junction box	T or X Channel	T for 3-way, X for 4-way crossroads
Branch to two monitor cables	Y Channel	Y_Output_Direction = "Forward" keeps both outputs same direction
Gradually shift cable run diagonally	S Channel	Bezier curve, specify Units_Over and Units_Up
Route around circular desk leg	C Channel	Set Arc_Angle for quarter (90°) or half (180°) circle
Transition cables up/down wall	Height Change Channel	Smooth vertical transitions

When Pattern Is Unclear

Ask these questions:

1. Path shape: Straight, corner, curve, or multi-junction?
2. Exit points: Where do cables enter/exit the channel?
3. Direction changes: 90°, 45°, or smooth curve?
4. Mounting surface: Flat wall, under desk, around obstacles?

Default: When unclear, use I Channel (straight) - user can connect multiple segments later.

Universal Parameters (All Channels)

Required Parameters (Always Define)

/*[Choose Part]*/
Base_Top_or_Both = "Both"; // [Base, Top, Both] - Export control

/*[Channel Size]*/
Channel_Width_in_Units = 1;          // Width in grid units (25mm each)
Channel_Internal_Height = 12;        // Interior height 12-72mm (6mm increments)

/*[Mounting Options]*/
Mounting_Method = "Threaded Snap Connector";
// Options: Threaded Snap Connector, Direct Multiboard Screw,
//          Direct Multipoint Screw, Magnet, Wood Screw, Flat

Mounting Method Selection

Method	Use When	Parameters Needed	Print Orientation
Threaded Snap Connector	OpenGrid/Multiboard with connectors	None (default)	Base flat, Top upside-down
Direct Multiboard Screw	Screw directly into board holes	None	Base flat (pre-drilled holes)
Direct Multipoint Screw	Honeycomb Storage Wall	None	Base flat (larger holes)
Magnet	Curved surfaces, repositionable	Magnet_Diameter, Magnet_Thickness	Base flat (magnet recesses)
Wood Screw	Direct wall/desk mounting	Wood_Screw_Thread_Diameter	Base flat (countersink holes)
Flat	Adhesive mounting, testing	None	Base flat (no mounting features)

Common mistake: Using Flat for production installs. This removes all mounting features - only use for adhesive mounting or prototyping.

Advanced Options (Modify Rarely)

/*[Advanced Options]*/
Grid_Size = 25;                      // ALWAYS 25 for OpenGrid compatibility
Profile_Type = "Original";           // [Original, v2.5] - BETA: v2.5 inverse clip
Flex_Compensation_Scaling = 0.99;    // For wide/tall channels, reduce flex
Additional_Holding_Strength = 0.0;   // [0:0.1:1.5] - Increase for larger channels

When to use Advanced Options:

• Profile_Type = "v2.5": BETA feature, inverse inside clip (not backwards compatible)
• Flex_Compensation_Scaling: Channels wider than 1 unit or taller than 18mm may flex - scale to 0.99
• Additional_Holding_Strength: Wide channels (2+ units) benefit from 0.6 extra holding strength

Code Generation Workflow

Step 1: Determine Channel Type

Use decision framework above → select appropriate channel file as reference.

Step 2: Read Channel-Specific Subpage

Navigate to relevant subpage for detailed parameter reference:

• ./straight-runs.md: I Channel (cord cutouts, length parameters)
• ./corners-junctions.md: L, T, X, Y Channels (arm lengths, mitered corners)
• ./curves-transitions.md: S, C, Mitre, Height Change (curve parameters, angles)
• ./mounting-accessories.md: Keyholes, Hooks, Item Holders, Connectors

Step 3: Gather User Requirements

Dimension questions:

• How wide should the channel be? (units × 25mm)
• How tall inside? (12mm min, 72mm max, 6mm increments)
• Length/distance for straight sections? (units × 25mm)

Mounting questions:

• Where mounting? (OpenGrid board, direct wall, desk underside)
• Mounting hardware available? (snap connectors, screws, magnets)

Cable exit questions:

• Where do cables exit? (for I Channel cord cutouts)
• How many cables? (affects cutout count/spacing)

Step 4: Generate OpenSCAD Code

Code structure pattern:

/*Created by [Your context]
Based on QuackWorks Underware by BlackjackDuck (Andy) and Hands on Katie
Licensed Creative Commons 4.0 Attribution Non-Commercial Share-Alike (CC-BY-NC-SA)

Documentation: https://handsonkatie.com/underware-2-0-the-made-to-measure-collection/
*/

include <BOSL2/std.scad>
include <BOSL2/rounding.scad>
include <BOSL2/threading.scad>

/*[Choose Part]*/
Base_Top_or_Both = "Both";

/*[Channel Size]*/
Channel_Width_in_Units = 1;
Channel_Internal_Height = 12;
// ... channel-specific size parameters

/*[Mounting Options]*/
Mounting_Method = "Threaded Snap Connector";
// ... mounting-specific parameters

/*[Advanced Options]*/
Grid_Size = 25;
Global_Color = "SlateBlue";
Profile_Type = "Original";

// ... include complete module code from QuackWorks reference

DO NOT write modules from scratch - copy/adapt from QuackWorks repository:

1. Fetch latest .scad file from QuackWorks
2. Preserve all module code (profiles, path_sweep operations)
3. Only modify user-facing parameters section
4. Keep attribution comments intact (CC BY-NC-SA license requirement)

Common Pitfalls

Pitfall #1: Hardcoding Dimensions Instead of Grid Units

Problem: User requests 75mm long channel, code sets lengthMM = 75.

Why it fails: Underware uses grid units for mounting alignment. 75mm doesn't align to 25mm grid - mounting holes won't match OpenGrid.

Better approach:

// User wants 75mm → suggest 75mm = 3 grid units
Channel_Length_Units = 3;  // 3 × 25mm = 75mm

// Or: User wants 80mm → explain rounding
Channel_Length_Units = 3;  // 75mm (closest grid alignment)
// Note to user: "Using 3 units (75mm) for grid alignment.
//                For 100mm use 4 units."

Pitfall #2: Ignoring Two-Part Export

Problem: Code generates only base or only top, user can't assemble.

Why it fails: Underware requires both parts to function. Base alone has no cable retention, top alone can't mount.

Better approach:

// ALWAYS default to Both for user convenience
Base_Top_or_Both = "Both";

// Explain in comments:
// For printing: Export "Both", slice with parts separated
// For troubleshooting: Export "Base" or "Top" individually

Pitfall #3: Wrong Mounting Method for Use Case

Problem: User mounting to OpenGrid, code uses Flat method.

Why it fails: No mounting features generated - channel won't attach.

Better approach:

// Ask about mounting surface first
// OpenGrid/Multiboard → "Threaded Snap Connector"
// Direct wall → "Wood Screw" with Wood_Screw_Thread_Diameter = 3.5
// Metal desk → "Magnet" with Magnet_Diameter = 4.0, Magnet_Thickness = 1.5

Pitfall #4: Forgetting BOSL2 Dependencies

Problem: User can't render code, errors about undefined path_sweep.

Why it fails: BOSL2 library not included or not installed in OpenSCAD.

Better approach:

// ALWAYS include these three at top of file:
include <BOSL2/std.scad>
include <BOSL2/rounding.scad>
include <BOSL2/threading.scad>

// Add comment explaining BOSL2 requirement:
// Requires BOSL2 library: https://github.com/BelfrySCAD/BOSL2
// Install: Download and place in OpenSCAD libraries folder

Pitfall #5: Using Beta Features Without Warning

Problem: Code sets Profile_Type = "v2.5" without explaining implications.

Why it fails: v2.5 inverse clip is not backwards compatible with Original profile. User can't mix old and new channels.

Better approach:

// Only use beta features if explicitly requested
Profile_Type = "Original";  // Default, backwards compatible

// If user wants stronger hold:
Additional_Holding_Strength = 0.6;  // Stable, works with Original

// If user explicitly requests beta:
// Profile_Type = "v2.5";  // BETA: Inverse clip, NOT compatible with Original profile

Quality Checklist

Before delivering OpenSCAD code:

QuackWorks compliance:

• ✓ Code copied from QuackWorks reference (not written from scratch)
• ✓ Attribution comments intact (CC BY-NC-SA license)
• ✓ BOSL2 includes present (std.scad, rounding.scad, threading.scad)
• ✓ Module structure preserved (baseProfile, topProfile functions)

Parameter validation:

• ✓ Grid_Size = 25 (never modified)
• ✓ Channel_Width_in_Units is integer (1, 2, 3, not 1.5)
• ✓ Channel_Internal_Height in 6mm increments (12, 18, 24, ... 72)
• ✓ Mounting method appropriate for user's surface
• ✓ Base_Top_or_Both = "Both" unless user needs individual parts

Dimensional sanity:

• ✓ Dimensions specified in grid units (not raw mm)
• ✓ Channel width accounts for cable bundle size + clearance
• ✓ Internal height sufficient for thickest cable + movement
• ✓ Length/arm dimensions align to 25mm grid for mounting

Channel-specific requirements:

• ✓ I Channel: Cord cutout count/spacing matches cable exit needs
• ✓ L Channel: X and Y axis lengths set independently
• ✓ T/X Channels: Mitered corners option considered for thick cables
• ✓ Y Channel: Output direction (Forward/Turn) matches user's layout
• ✓ S/C Channels: Curve parameters create smooth transitions (no sharp bends)

User communication:

• ✓ Explained channel type selection rationale
• ✓ Noted any dimension rounding to grid units
• ✓ Documented mounting method choice
• ✓ Warned if using beta features (v2.5 profile)
• ✓ Provided print orientation guidance (Base flat, Top upside-down)

Navigation: Channel-Specific Reference

Read these subpages for detailed parameter reference:

Subpage	Contains	Use For
./straight-runs.md	I Channel (straight with cord cutouts)	Linear cable runs, desktop cable management
./corners-junctions.md	L, T, X, Y Channels	Corner turns, multi-path junctions, cable splits
./curves-transitions.md	S, C, Mitre, Height Change Channels	Smooth curves, diagonal transitions, vertical routing
./mounting-accessories.md	Keyholes, Hooks, Item Holders, Connectors	Wall mounting, accessory integration, modular connections

Documentation References

Official Underware sources:

• QuackWorks GitHub: https://github.com/AndyLevesque/QuackWorks/tree/main/Underware
• Hands on Katie guide: https://handsonkatie.com/underware-2-0-the-made-to-measure-collection/
• License: CC BY-NC-SA 4.0

BOSL2 library:

• GitHub: https://github.com/BelfrySCAD/BOSL2
• Documentation: https://github.com/BelfrySCAD/BOSL2/wiki
• Required for all Underware code generation

Related spirograph skills:

• home-organization/SKILL.md: System selection (when to use Underware vs other systems)
• opengrid-openscad/SKILL.md: OpenGrid accessory code generation (complementary system)

Ecosystem integration:

• Underware integrates natively with OpenGrid mounting systems
• Use OpenGrid boards under desk, snap Underware channels into grid
• See home-organization skill for Underware + OpenGrid combination strategies