1/4" hex shank to 11/32" hex socket adapter SCAD file

hex_1_4_inch_male_to_11_32_inch_female_adapter.scad

/*
 * Hex Bit Adapter: Converts a 1/4 inch (6.35 mm) male hex shank to an 11/32 inch (8.73 mm) female hex socket.
 */

epsilon = 0.01; // Small value (0.01 mm) to ensure proper overlap or gap for boolean operations.

// --- Parameters ---
male_hex_size_nominal = 6.35; // Nominal size of the male hex shank: 1/4 inch (6.35 mm)
male_hex_fit_tolerance = -0.1; // Tolerance for the male hex shank, negative for undersize (-0.1 mm) to ensure easier fit.
male_hex_af = male_hex_size_nominal + male_hex_fit_tolerance; // Across Flats dimension of the male hex shank.
male_hex_length = 10; // Length of the male hex shank (10 mm).

female_hex_size_nominal = 8.73; // Nominal size of the female hex socket: 11/32 inch (approximately 8.73 mm)
female_hex_fit_tolerance = 0.2; // Tolerance for the female hex socket, positive for oversize (+0.2 mm) to allow the bit to fit.
female_hex_af = female_hex_size_nominal + female_hex_fit_tolerance; // Across Flats dimension of the female hex socket.
female_hex_depth = 12; // Depth of the female hex socket (12 mm).

body_diameter = 15; // Diameter of the main body of the adapter (15 mm).
body_transition_length = 3; // Length of the solid cylindrical part between the end of the male shank and the bottom of the female socket (3 mm).
total_length = male_hex_length + body_transition_length + female_hex_depth; // Total length of the hex bit adapter.

// --- Quality ---
$fn = 60; // Resolution for curved surfaces (number of facets for circles). Higher values result in smoother curves.

// --- Helper Calculations ---
male_hex_radius_vert = (male_hex_af / 2) / cos(30); // Calculated vertical radius (distance from center to a flat side) of the male hex.
female_hex_radius_vert = (female_hex_af / 2) / cos(30); // Calculated vertical radius (distance from center to a flat side) of the female hex.

// --- Geometry ---

difference() { // Creates the adapter by subtracting the female socket from the main body with the male shank.
    // --- Main Positive Shape (Simple Union of Male Shank and Body) ---
    union() { // Combines the male hex shank and the main body into a single solid shape.
        // Male Hex Shank Prism
        cylinder(h = male_hex_length, r = male_hex_radius_vert, $fn=6, center=false); // Creates the hexagonal prism of the male shank.

        // Main Body Cylinder
        translate([0, 0, male_hex_length]) // Moves the main body cylinder to start at the end of the male shank.
            cylinder(h = body_transition_length + female_hex_depth, d = body_diameter, center=false, $fn=$fn); // Creates the cylindrical body of the adapter.
    } // End Union

    // --- Female Socket Cutout (Hexagonal Cylinder) ---
    socket_bottom_z = male_hex_length + body_transition_length; // Z-coordinate for the bottom of the female socket.
    translate([0, 0, socket_bottom_z]) // Moves the cutting cylinder to the correct starting position.
        cylinder(h = female_hex_depth + epsilon, r = female_hex_radius_vert, $fn=6, center=false); // Creates the hexagonal hole for the female socket, extending slightly to ensure a full cut.

} // End Difference