How to Run the Heatsink Designer in FreeCAD

Prerequisites

1. Install FreeCAD (Version 0.20 or later recommended)
2. Make sure Python is included in your FreeCAD installation (it usually is by default)

Setting Up the Macro

1. Open FreeCAD
2. Go to Tools → Macro → Macros... in the top menu
3. In the Macro dialog:
   • Click "Create"
   • Name your macro (e.g., "heatsink_designer.py", or "heatsink_designer.FCMacro")
   • Click "OK"
4. In the macro editor that opens:
   • Delete any existing code
   • Copy and paste the entire heatsink designer code
   • Click "Save"
   • Close the editor

Running the Macro

1. Go to Tools → Macro → Macros... again
2. Select your heatsink macro from the list
3. Click "Execute"

Using the Designer

When you run the macro, you'll see a dialog box asking for:

1. Base Size (50-200mm):

   • This is the main dimension of your heatsink
   • Default is 100mm
   • Use larger values for bigger heatsinks

2. Number of Designs (1-15):

   • Choose how many different designs to generate
   • Maximum is 15 to prevent FreeCAD from crashing
   • Recommended to start with 5-6 designs

3. After clicking "OK", you'll need to:

   • Select a folder where you want to save the results
   • Wait while the designs are generated

Output Files

The program will create three files in your selected folder:

1. A FreeCAD file (.FCStd) containing all 3D models
2. A CSV file with measurements and performance data
3. A summary report of the designs

Viewing Results

1. The 3D designs will appear automatically in FreeCAD:

   • Different colors for each design
   • Arranged in a grid layout
   • You can rotate and zoom to inspect them

2. A summary window will show:

   • Number of designs created
   • Pattern types used
   • Average heat dissipation
   • Best performing design

Tips

• Start with a small number of designs (3-4) for your first try
• The designs are random, so running the macro multiple times will give different results
• You can open the CSV file in Excel to analyze the designs
• Use FreeCAD's measurement tools to inspect the 3D models

Troubleshooting

• If FreeCAD becomes slow: Try generating fewer designs
• If designs look too small/large: Adjust the base size
• If the program crashes: Restart FreeCAD and try with fewer designs

Notes

• Each design will be randomly generated with different:
  • Fin patterns (straight, angled, or zigzag)
  • Dimensions
  • Colors
• The program calculates:
  • Heat dissipation
  • Weight
  • Surface area
  • Manufacturing complexity