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=== Profile ===
{{Parts infobox
Replimat frames are constructed of individual frame sections with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece or laminated or joined cut sheet.  All Replimat frame sections share the same width, which is 1.5 inches (38.1 millimeters) across each side. Frames of larger or smaller widths may be produced, and continue to work with all of the construction techniques found here. 
|image          = Frame-5.png
|designers      = Phil Jergenson, Ken Isaacs, Tim Schmidt
|date            = 1987
|vitamins        =  
|materials      = [[Woods]], [[Aluminums]], [[Steels]], [[Plastics]], [[Fiber reinforced resins]]
|transformations = [[Milling]], [[Drilling]], [[Punching]], [[Cutting]]
|lifecycles      =  
|tools          = [[Drill presses]], [[Automated drilling machines]], [[CNC routers]], [[Punch presses]], [[Sanding blocks]]
|parts          =
|techniques     = [[Bolting]], [[Tri joints]], [[Shelf joints]], [[Count by fives]], [[Divisible by two]], [[Center holes]]
|files          =
|suppliers      =
|git            =
}}


=== Hole Pattern ===
[[Category:Parts]]
[[Category:Structure parts]]
 
=Introduction=
The modular frames in this system are constructed using only one component, repeated and assembled in a variety of configurations attached using [[nuts]], [[bolts]], and [[washers]].  These frames assemble quickly, intuitively, and squarely in all dimensions and on uneven surfaces, under water, or in zero gravity.  Frame members are easily manufactured from renewable and widely available raw  materials such as trees, square steel, aluminum, and other metal tube, even bamboo and
recycled thermoplastics.  Aluminum frame members retain perfect interchangeability and reusability after years of
intense sun exposure, submersion in water, etc.  Wood frame members retain near-perfect interchangeability and reusability across lifetimes when stored in a home, or other controlled environment.
 
=Challenges=
Most projects require a physical structure.  Sizes, shapes, and configurations vary widely.  Welding requires special skills and equipment.  Aluminum extrusion, widely used, can be frustrating to insert nuts into channels in already assembled frames, and the infinite adjustability of the extruded channel requires measurement tools at assembly time and great care and attention to detail.
 
<youtube>IcVu7G71N50</youtube>
<youtube>x30Sq6aq0wY</youtube>
 
=Approaches=
Construct projects using a standardized [https://en.wikipedia.org/wiki/Space_frame space frame] kit optimized for local production.  Unlike Isaacs or Jergensen frames, Replimat uses only lengths that are multiples of 5 segments: 200 mm or approximately 7.5 inches. Frames of two, three, and four segment lengths are included to allow for the construction of additional joints and assemblies.
<gallery>
Perforatedtube.jpg|
Flat pack frame.jpg|
Delivery.jpg|
Frame delivery.jpg|
Flat pack frame2.jpg|Flat pack frame by [https://twitter.com/Ian_Willey/status/610420168783724544 Ian Willey]
</gallery>
 
<youtube>avdOxtKywbk</youtube>
 
==Profile==
Replimat frames are constructed using standard lengths of material with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece, laminated, or joined.  All Replimat frame sections share the same 40mm width. Frames of larger or smaller widths may be produced, and work with all of the construction techniques found here.  Frames of evenly divisible widths interoperate.
 
Spaceframes constructed similarly are possible using other profiles.  Hexagonal profile frame may be capable of building sections of [https://en.wikipedia.org/wiki/Weaire%E2%80%93Phelan_structure Weaire–Phelan structures].
 
== Hole Pattern ==
Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.
Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.


=== Lengths ===
==Widths==
Frame lengths are intentionally limited to 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 50, 60, 80, and 100 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations (using lengths 2, 3, 4, and 5) as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. The reduced set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping.
Frames of larger cross section require fewer holes than frames of smaller cross section that are the same length.  And fewer saw cuts when working from lumber or [[sheets]].  Counterintuitively, thicker frame is sometimes faster or less expensive to produce than thinner frame.  Thicker frame also creates stronger [[tri joints]] and requires fewer nuts and bolts to create frames of equivalent size and strength as compared to frame of reduced width.  Thinner frame can allow accurate and reproducible model building before final assembly at larger scale.  Thinner frame also allows for a finer resolution in the hole pattern, easing complex mounting problems.
 
==Lengths==
Replimat uses frame lengths of 2, 3, 4, 5, 10, 15, 20, 25, and 30 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. Reducing the set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping.  Projects in this wiki make use of only these 9 lengths and rely on [[trusses]], [[splicing frames]], [[stacked washers]], and adapter [[plates]] to reach arbitrary positions.


=== Nuts and bolts ===
{| class="wikitable"
Frame sections are joined together using three lengths of bolt, suitable for 1, 2, or 3 stacked frames and share a single size washer and nut.
|+ Comparison of whole unit frame lengths - 200mm has been chosen as a base unit
|-
! 8mm width !! 20mm width !! 25.4mm width !! 38.1mm width !! 40mm width !! 50mm width !! 60mm width
|-
| 8mm ||  ||  ||  ||  ||  ||
|-
| 16mm ||  ||  ||  ||  ||  ||
|-
| 24mm ||  || 25.4mm ||  ||  ||  ||
|-
| 32mm ||  ||  ||  ||  ||  ||
|-
| 40mm || 40mm ||  ||  || 40mm ||  ||
|-
| 48mm ||  || 50.8mm ||  ||  || 50mm ||
|-
| 56mm ||  ||  ||  ||  ||  ||
|-
| 64mm ||  ||  ||  ||  ||  ||
|-
| 72mm ||  ||  ||  ||  ||  ||
|-
| 80mm || 80mm || 76.2mm || 76.2mm || 80mm || ||
|-
| 88mm ||  ||  ||  ||  ||  ||
|-
| 96mm ||  ||  ||  ||  ||  ||
|-
| 104mm ||  || 101.2mm ||  ||  || 100mm ||
|-
| 112mm ||  ||  || 114.3 ||  ||  ||
|-
| 120mm || 120mm ||  ||  || 120mm  ||  || 120mm
|-
| 128mm ||  || 126.6mm ||  ||  ||  ||
|-
| 136mm ||  ||  ||  ||  ||  ||
|-
| 144mm ||  ||  ||  ||  ||  ||
|-
| 152mm ||  || 152.4mm || 152mm ||  || 150mm ||
|-
| 160mm || 160mm ||  ||  || 160mm ||  ||
|-
| 168mm ||  ||  ||  ||  ||  ||
|-
| 176mm ||  || 177.4mm ||  ||  ||  ||
|-
| 184mm ||  ||  ||  ||  ||  || 180mm
|-
| 192mm ||  ||  || 190.5 ||  ||  ||
|-
| 200mm || 200mm || 202.8mm ||  || 200mm || 200mm ||
|-
| 208mm ||  ||  ||  ||  ||  ||
|-
| 216mm ||  ||  ||  ||  ||  ||
|-
| 224mm || 220mm || 228.6 || 228.6 ||  ||  ||
|}


=== Tools ===
<gallery>
Frame assembly requires two 13mm wrenches. A socket wrench or battery powered electric socket wrench are highly recommended for quick and easy [dis]assembly.
Frame-2.png|2 hole frame - smallest frame useful for making [[tri joints]]
Frame-3.png|3 hole frame - often useful to create spurs, mount points, and [[clevis fasteners]], smallest of the frames with [[center holes]]
Frame-4.png|4 hole frame - sometimes required for linkages and structural elements
Frame-5.png|5 hole frame - [[count by fives]] which have [[center holes]] and can accommodate two [[tri joints]] each
Frame-10.png|10 hole frame - "a ten"
Frame-15.png|15 hole frame - this size works great for larger pivoting mechanisms thanks to it's [[center holes|center hole]]
Frame-20.png|20 hole frame - desk or counter top height
Frame-25.png|25 hole frame - the largest of the frames with [[center holes]]
Frame-30.png|30 hole frame - makes great shelves
</gallery>


=== Joints ===
==Variations==
Three frame sections can be joined with three nuts and bolts to form a strong three dimensional joint orienting each frame section perpendicular to the others.  Other joining techniques allow for triangular and hinged joints, which are sufficient to build several useful linkages including the Peaucellier–Lipkin linear motion linkage, Jansen’s linkage, leading link suspension, and more.
In the imperial version, popular hole sizes are 21/64 inch and popular bolt sizes are 5/16 inch. For the metric frames, we can use a 6 mm bolt and 7-8 mm holes for the 25 mm frame; a 12 mm bolt and holes for the 40 mm frame and 13-14 mm holes for the 50 mm frame.


=== Suppliers ===
==Materials==
====Steel / Aluminum====
[http://en.wikibooks.org/wiki/Robotics/Design_Basics/Building_Materials Wikibooks: robot building materials] implies that cardboard (!) is best for quick prototypes; for functional robots, "wood is probably the best material to start with."; where wood isn't quite durable enough, aluminum is the best metal -- better than steel for most robots.
=====United states=====
===Steel / Aluminum===
====United states====
*Any construction steel supplier.
*Any construction steel supplier.
* [https://8020.net/9701.html 8020 Inc]
* [https://8020.net/9701.html 8020 Inc Ready Tube]
* [https://www.boschrexroth.com/en/xc/products/product-groups/assembly-technology/topics/aluminum-profiles-solutions-components/index Bosch Rexroth Profiles]
* [https://www.mcmaster.com/Standard-Bolt-Together-Structural-Framing McMaster-Carr Bolt-Together Framing]
* [https://www.item24.de/en/home.html item Aluminum Profiles (the original)]
* [http://www.atc-mechanical.com/telespar/square-sign-post/ Allied Tube Telespar and Quick-Punch]
* [https://www.mk-group.com/en/products/profile-technology/profile-system.html MK Aluminum Profile System]
* [http://www.atc-mechanical.com/mechanical-tubing/square-fit-steel-tubing/ Allied Tube Square-Fit]
* [https://www.mcmaster.com/square-tubing McMaster]
* [http://www.s-squaretube.com/Products/ProductDetails/tabid/85/ProductID/13/Default.aspx S-Square Square Post Perforated]
* [http://www.atc-mechanical.com/telespar/square-sign-post/ Telespar 2"]
* Ultimate Highway Products Ulti-Mate steel highway sign posts
*   [https://www.unistrutohio.com/telespar Unistrut Telespar Ohio]
* [https://www.hemptraders.com/ Hemptraders]
=====Canada=====
* [https://www.markstaar.com Markstaar recycled plastic lumber]
*Any construction steel supplier.
* [https://www.tnutz.com/ TNutz]
*Unistrut
 
=====UK=====
====Canada====
* Any construction steel supplier.
* Unistrut
* [https://makerparts.ca/ Makerparts.ca]
* [https://spool3d.ca/parts/aluminum-extrusion/ Spool3D.ca]
* [https://us.misumi-ec.com/service/promotion/canada/ Misumi Canada]
* [https://store.cpiautomation.com/ CPI Automation]
 
====UK====
*Any construction steel supplier.  (Undrilled)
*Any construction steel supplier.  (Undrilled)
=====New Zealand=====
====New Zealand====
<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<VikOlliver> Strangley it's in approx 25mm increments...
<VikOlliver> Strangley it's in approx 25mm increments...
* sbailard_ is beside himself in surprise.
* sbailard_ is beside himself in surprise.
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...


===Wood===
* https://www.ullrich-aluminium.co.nz/extrusions/square-tube
===Warning====
* https://www.easysteel.co.nz/products/hollow-sections
In North America, {{tag|wood}} which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross section. This is unfortunate but legal. Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'. They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job. (If you are a woodworker, this paragraph is obvious, and we apologize. And you have a table saw.)


====Imperial====
====China====
*1"x1" or 2"x2"
* [https://www.aliexpress.com/store/1752067?spm=2114.12010612.pcShopHead_12407346.0 Bulkman 3D]
====Metric====
18mm x 18mm or 44mm x 44mm (Metric)


Back in the our imperial days these would have been called 1"x1" & 2"x2"
===Wood===
====Michigan====
* [https://www.michigan.gov/documents/dnr/industry_directory_535236_7.pdf WOOD PRODUCTS IN MICHIGAN PART I - A Directory of Primary Mills and Manufacturers]


Which should have been 25.4mm x 25.4mm and 50.8mm x 50.8mm now its shown as its true size in mm.
====Warning====
 
In North America, wood which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross sectionThis is unfortunate but legal.  Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'.  They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job.  (If you are a woodworker, this paragraph is obvious, and we apologize.  And you have a table saw.)
==Wood Construction Debris==
It's plausible that we can use Eiffel or similar to mill construction debris wood down to 1"x1".   
It's plausible that we can use Eiffel or similar to mill construction debris wood down to
*1"x1" or 2"x2" (Imperial)
*18mm x 18mm or 44mm x 44mm (Metric)


A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch)
A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch)
can be ripped and planed into two separate grid beams (each 38 mm square).
can be ripped and planed into two separate grid beams (each 38 mm square).
Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?  
Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?


====Notes====
*Nails - After checking carefully with a nail finder.
*Nails - After checking carefully with a nail finder.
*Grit - Use a stiff plastic brush to clean off your wood.  Stone pebbles will chip your saw blade.
*Grit - Use a stiff plastic brush to clean off your wood.  Stone pebbles will chip your saw blade.


===Similar Construction Systems===
===Plastics===
====Dexion Speedframe====
<youtube>zNGuuSKE1pY</youtube>
This is a high-strength shelving system made from cheap steel square tubes and unimportant but elegant interconnectors.
 
The tubes are a lovely 1" (25.4mm) square x 10 ft (3048mm aka '3m') long.
 
*Speedframe (1" square x 3048mm long) x 1 length
£20.00 per 3m length
http://www.tradesystems.co.uk/acatalog/Dexion-SpeedFrame-25mm-Square-Tube-System.html?gclid=CO20puGvvJ4CFQQMDQodVCn5Cg
 
*'''Buy Used!''' Shelving outlives many a business plan, so check your telephone directory under 'shelving/racking'. 
You may get lucky, and pay £10/3m rather than £20/3m.
http://shop.instant-shop.com/stodec/category740226.html


*Used/offbrand
=References=
http://www.richardsonsuk.co.uk/productdetails.php?product=74
* [https://hackaday.com/2021/05/25/getting-started-with-aluminum-extrusions/ Getting started with aluminum extrusions]
* https://www.amazon.com/dp/B07P7BKXY7/ref=cm_sw_r_cp_apa_i_w83gFbG078T8M?tag=replimat-20
* [https://hackaday.com/2016/12/14/a-how-to-in-homebrew-design-fab-and-assembly-with-extruded-profiles/#more-232250 A How-To in Homebrew Design, Fab, and Assembly With Extruded Profiles]
* [https://ssb.muchmuch.coffee/%25bUttGn66HTaK16QNp7XBB%2B4fWlNnTPpOfpIUfRxHX3s%3D.sha256 discussion of frame production techniques]
* [https://www.atthatmatt.com/research/grand-unification-theory-of-modular-units/ Grand unification theory of modular units]
* [https://tojagrid.com Toja grid pergola system] - 4x4 brackets are 14-gauge and 6x6 brackets are 12-gauge steel, 10 year powder coating, 5 year warranty.
* [https://github.com/marialarsson/tsugite Interactive Design and Fabrication of Wood Joints]
* [https://www.bullmoosetube.com/wp-content/uploads/2020/06/HSS_Beam_Load_Tables.pdf HOLLOW  STRUCTURAL SECTIONS Beam Load Tables]
* [https://sacr3detching.com/ Sacr3D Etching]
<youtube>ozSE7Wrdb1o</youtube>

Latest revision as of 06:49, 4 March 2023

Introduction

The modular frames in this system are constructed using only one component, repeated and assembled in a variety of configurations attached using nuts, bolts, and washers. These frames assemble quickly, intuitively, and squarely in all dimensions and on uneven surfaces, under water, or in zero gravity. Frame members are easily manufactured from renewable and widely available raw materials such as trees, square steel, aluminum, and other metal tube, even bamboo and recycled thermoplastics. Aluminum frame members retain perfect interchangeability and reusability after years of intense sun exposure, submersion in water, etc. Wood frame members retain near-perfect interchangeability and reusability across lifetimes when stored in a home, or other controlled environment.

Challenges

Most projects require a physical structure. Sizes, shapes, and configurations vary widely. Welding requires special skills and equipment. Aluminum extrusion, widely used, can be frustrating to insert nuts into channels in already assembled frames, and the infinite adjustability of the extruded channel requires measurement tools at assembly time and great care and attention to detail.

Approaches

Construct projects using a standardized space frame kit optimized for local production. Unlike Isaacs or Jergensen frames, Replimat uses only lengths that are multiples of 5 segments: 200 mm or approximately 7.5 inches. Frames of two, three, and four segment lengths are included to allow for the construction of additional joints and assemblies.

Profile

Replimat frames are constructed using standard lengths of material with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece, laminated, or joined. All Replimat frame sections share the same 40mm width. Frames of larger or smaller widths may be produced, and work with all of the construction techniques found here. Frames of evenly divisible widths interoperate.

Spaceframes constructed similarly are possible using other profiles. Hexagonal profile frame may be capable of building sections of Weaire–Phelan structures.

Hole Pattern

Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.

Widths

Frames of larger cross section require fewer holes than frames of smaller cross section that are the same length. And fewer saw cuts when working from lumber or sheets. Counterintuitively, thicker frame is sometimes faster or less expensive to produce than thinner frame. Thicker frame also creates stronger tri joints and requires fewer nuts and bolts to create frames of equivalent size and strength as compared to frame of reduced width. Thinner frame can allow accurate and reproducible model building before final assembly at larger scale. Thinner frame also allows for a finer resolution in the hole pattern, easing complex mounting problems.

Lengths

Replimat uses frame lengths of 2, 3, 4, 5, 10, 15, 20, 25, and 30 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. Reducing the set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping. Projects in this wiki make use of only these 9 lengths and rely on trusses, splicing frames, stacked washers, and adapter plates to reach arbitrary positions.

Comparison of whole unit frame lengths - 200mm has been chosen as a base unit
8mm width 20mm width 25.4mm width 38.1mm width 40mm width 50mm width 60mm width
8mm
16mm
24mm 25.4mm
32mm
40mm 40mm 40mm
48mm 50.8mm 50mm
56mm
64mm
72mm
80mm 80mm 76.2mm 76.2mm 80mm
88mm
96mm
104mm 101.2mm 100mm
112mm 114.3
120mm 120mm 120mm 120mm
128mm 126.6mm
136mm
144mm
152mm 152.4mm 152mm 150mm
160mm 160mm 160mm
168mm
176mm 177.4mm
184mm 180mm
192mm 190.5
200mm 200mm 202.8mm 200mm 200mm
208mm
216mm
224mm 220mm 228.6 228.6

Variations

In the imperial version, popular hole sizes are 21/64 inch and popular bolt sizes are 5/16 inch. For the metric frames, we can use a 6 mm bolt and 7-8 mm holes for the 25 mm frame; a 12 mm bolt and holes for the 40 mm frame and 13-14 mm holes for the 50 mm frame.

Materials

Wikibooks: robot building materials implies that cardboard (!) is best for quick prototypes; for functional robots, "wood is probably the best material to start with."; where wood isn't quite durable enough, aluminum is the best metal -- better than steel for most robots.

Steel / Aluminum

United states

Canada

UK

  • Any construction steel supplier. (Undrilled)

New Zealand

<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<VikOlliver> Strangley it's in approx 25mm increments...
* sbailard_ is beside himself in surprise.
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...

China

Wood

Michigan

Warning

In North America, wood which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross section. This is unfortunate but legal. Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'. They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job. (If you are a woodworker, this paragraph is obvious, and we apologize. And you have a table saw.)

A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch) can be ripped and planed into two separate grid beams (each 38 mm square). Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?

  • Nails - After checking carefully with a nail finder.
  • Grit - Use a stiff plastic brush to clean off your wood. Stone pebbles will chip your saw blade.

Plastics

References