The problem I had with the minkowski sum is that I forgot it adds the one object all over the other, so my tool head was twice as tall. I probably could have doen this in 2d and extruded, but instead I just wanted to move ahead and compensated. (This is one of those cases that a ruler on the screen would have helped, as I would have realized sooner that this is what was going on.) As an aside - don't try to scale by '0' - it doesn't like that and crashes.

I rounded one of the edges by rotating a circle to get a torus. I also created the little grip bars by joining a cylinder and a sphere (and then I rotated that in a for loop to place it around the handle). I didn't bother hollowing out the handle.

It seems to me that if you up the value of $fn just a little, the CGAL render time goes up a *lot*. Bumping it to 50 (just for the handle) made the time go from nothing to almost five minutes.

Here is the end result:

And the code

include <MCAD/shapes.scad> TOOL_HEIGHT = 14; FLAT_PART_THICKNESS = 1; module wrench_head_part() { difference() { cylinder(h = TOOL_HEIGHT, r = 22.5); translate([7.5, 0, TOOL_HEIGHT/2]) hexagon(25, TOOL_HEIGHT); translate([14, -12.5, 0]) cube([25, 25, TOOL_HEIGHT]); } } module outer_hull() { scale([1, 1, 0.5]) minkowski() { wrench_head_part(); cylinder(h = TOOL_HEIGHT , r = 1); } } module full_wrench_head() { difference() { outer_hull(); translate([0, 0, (TOOL_HEIGHT/2) + FLAT_PART_THICKNESS]) wrench_head_part(); translate([0, 0, -(TOOL_HEIGHT/2) - FLAT_PART_THICKNESS]) wrench_head_part(); } } module stem() { difference() { rotate([0, 90, 0]) cylinder(h = 37, r=8); translate([-.5, -7, FLAT_PART_THICKNESS]) cube([38, 14, 10]); translate([-.5, -7, -10 - FLAT_PART_THICKNESS]) cube([38, 14, 10]); } } module grip_bar() { $fn = 50; rotate([0, 90, 0]) linear_extrude(height = 59) circle(1); translate([59, 0, 0]) sphere(1); } module handle() { $fn = 50; translate([-75, 0, 0]) rotate([0, 90, 0]) cylinder(h = 60, r=14); translate([-15, 0, 0]) rotate([0, 90, 0]) cylinder(h = 15, r=13); rotate([0, 90, 0]) cylinder(h = 5, r1 = 13, r2 = 8); translate([-75, 0, 0]) rotate([0, 90, 0]) cylinder(h = 3, r=15); for (i=[0:7]) { rotate(i*45, v=[1, 0, 0]) translate([-75, 14, 0]) grip_bar(); } translate([-15, 0, 0]) rotate([0, 90, 0]) rotate_extrude(convexity = 10) translate([13, 0, 0]) circle(r = 1); } module wrench() { union() { translate([0, 0, -TOOL_HEIGHT/2]) rotate([0, 0, -14]) full_wrench_head(); difference() { translate([-37 - 20, 0, 0]) stem(); translate([0, 0, -TOOL_HEIGHT/2]) rotate([0, 0, -14]) outer_hull(); } translate([-42 - 20, 0, 0]) handle(); } } wrench();

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