thermal-block-insert

// Thermal Block Insert
// Interlocking insulation insert for masonry walls, designed with a tongue-and-groove profile for modular alignment and thermal efficiency

// Set units in millimeters (mm)
@settings(defaultLengthUnit = mm, kclVersion = 1.0)

// Define overall dimensions of the insert block
insertLength = 400
insertHeight = 200
insertThickness = 50

// Define tongue-and-groove profile parameters for interlocking geometry
setbackFactor = 0.25 // spacing between tongues
tongueTargetCount = insertLength / 80
tongueCount = round(tongueTargetCount)
tongueLength = insertLength / (tongueCount * (1 + setbackFactor * 2) + 1)
tongueGap = tongueLength * setbackFactor * 2
tongueStep = tongueLength + tongueGap
tongueDepth = tongueLength * 0.5
tongueSetback = tongueLength * setbackFactor

// Function to create one side of the repeating tongue geometry along the block edge
fn tongueBlockFn() {
  tongueSingleBlock = xLine(length = tongueLength)
    |> line(end = [-tongueSetback, tongueDepth])
    |> xLine(length = tongueLength)
    |> line(end = [-tongueSetback, -tongueDepth])
    |> patternLinear2d(
         %,
         instances = tongueCount,
         distance = tongueStep,
         axis = [1, 0],
       )
    |> xLine(length = tongueLength)
  return tongueSingleBlock
}

// Create top-side profile with tongues
tongueShape = startSketchOn(XY)
  |> startProfile(%, at = [-insertLength / 2, insertThickness / 2])
  |> tongueBlockFn()
  |> yLine(length = -insertThickness / 2)
  |> xLine(length = -insertLength)
  |> close(%)

// Create bottom-side profile with grooves (inverse of tongue)
grooveShape = startSketchOn(XY)
  |> startProfile(
       %,
       at = [
         -insertLength / 2,
         -insertThickness / 2 - tongueDepth
       ],
     )
  |> tongueBlockFn()
  |> yLine(length = insertThickness / 2 + tongueDepth)
  |> xLine(length = -insertLength)
  |> close(%)

// Extrude both tongue and groove profiles to form the final thermal insert block
insertShape = extrude([tongueShape, grooveShape], length = insertHeight)