3 // Hard case for Fairphone 2
5 // Copyright 2018 Ian Jackson. There is NO WARRANTY.
6 // See below for full licensing and disclaimer.
10 // 1. You will want to git clone this repository.
12 // 2. Decide about the notification LED aperture. See the variable
13 // led_window_style, below. The default here is "ad-hoc
14 // multi-colour", which can produces a translucent (clear-ish)
15 // window set into the lid, even on a single-nozzle printer.
16 // See "Ad-hoc multi-colour", below.
18 // 3. use "make" to generate the necessary files:
20 // make -j8 fairphone-case.auto.scads `for f in \
26 // ; do echo fairphone-case,$f.auto.stl; done`
28 // 4. Print them. Case and OneKeeperPrint should probably be
31 // For Lid and LidWindowPrint, if you are doing ad-hoc
33 // i. Set up for clear filament
34 // ii. Print LidWindowPrint. Wait for it to finish.
35 // It won't take long. As soon as it finishes, tell
36 // your printer to warm up (so that in fact it does
38 // iii. Leaving the output so far on the printbed, reload
39 // your printer with the main lid colour.
40 // iv. Print LidPrint. You can let this go unattended.
42 // 5. Assemble the hinge. You will need 4x M2 12mm machine screws
43 // and 8x M2 full nuts.
45 // Make sure you get the hinge the right way round. If you're not
47 // openscad fairphone-case,DemoHinge.auto.scad
48 // to see an assembly diagram.
50 // The nuts recess into the hinge. You will want very fine
51 // pliers. As you screw each screw in, add the second nut when
52 // the screw thread emerges from the first - this will be a
53 // locknut. Screw each screw to an appropriate tightness for the
54 // hinge stiffness. You want the lid-side hinge to be stiffer as
55 // that makes closing the case work better.
57 // When you have the stiffness right, tighten the locknuts onto
62 // - To put the phone in, drop its RH side into the RH side of
63 // the case. Then feed the keeper through the small hole.
64 // Feed it right through.
66 // - The optional prop can be used to prop the phone up (in
67 // portrait orientation only right now). See
68 // openscad fairphone-case,DemoPropAngles.auto.scad
70 // Ad-hoc multi-colour
72 // This file is set up to let you make a translucent window using a
73 // single-extruder printer, using a "two print run" technique. This
74 // works well with our Lulzbot TAZ 5 and Aleph Objects' version of
75 // Cura. If you are using a different printer, you may need to
76 // adjust the parameters or try a different technique. In particular,
77 // initial_layer_thick
78 // set so that the window is one layer thick
79 // initial_layer_width
80 // set so that the slicer draws a rectangle around the whole
81 // object, rather than putting a "skirt" or anything inside
83 // If you have a dual-extruder printer, you can set led_window_style
84 // to 2 and do a single print of LidPrint and LidWindowPrint.
86 // Alternatively you can set it to 1 (just a hole) or 0 (no hole).
88 // Thanks to Clare Boothby for the ad-hoc multi-colour technique (and
89 // the parameters for our Lulzbot TAZ 5 and Aleph Objects's Cura).
93 // It might well be possible to adapt this file for other phones.
94 // If you do, let me know how you get on.
97 // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY
99 // Copyright (C)2018 Ian Jackson.
101 // This program for generating a 3D model is free software: you can
102 // redistribute it and/or modify it under the terms of the GNU
103 // General Public License as published by the Free Software
104 // Foundation, either version 3 of the License, or (at your option)
105 // any later version.
107 // This program is distributed in the hope that it will be useful,
108 // but WITHOUT ANY WARRANTY; without even the implied warranty of
109 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
110 // GNU General Public License for more details.
112 // You should have received a copy of the GNU General Public
113 // License along with this program. If not, see
114 // <http://www.gnu.org/licenses/>.
116 // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY
117 // PROTECT YOUR PHONE ! It is your responsibility to decide whether
118 // this case will meet your needs.
122 phone = [ 75.0, 145.0 ];
124 prop_buildout_less = 3;
126 prop_angles = [ 15, 30, 45, 60 ];
128 bumper = [ 0.250, -0.025 ];
129 // ^ One side. Overall size is increased by twice this.
130 // If no bumpers, is the gap around the phone.
134 led_window_style = 3;
136 // 1: simply an opening
137 // 2: opening with separate cover model, for printing in clear (two colour)
138 // 3: like 2 but one-layer window for ad-hoc multi-colour
140 initial_layer_thick = 0.400; // ^ needed for mode 3 only
141 initial_layer_width = 0.750; // ^ needed for mode 3 only
142 multicolour_gap = 0.15; // each side
145 phone_rim_depth = 0.80; // includes allowance for a screen protector
147 button_cutout_depth = 9;
149 phone_edge_thick = 9.0;
150 phone_total_thick = 12.0;
151 phone_backside_slope_inner = 1.5; // larger means shallower
152 phone_backside_slope_outer = 1.0; // larger means shallower
154 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
155 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
157 jack_pos = [ 13.83, 8.485 ];
158 jack_dia = 10.64 + .5; // some jack I had lying around
160 led_pos = [ 13.98, 10.00 ];
162 led_window_ledge = 0.75; // each side
164 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
165 noisecancelmic_dia = 4.00;
167 //fingerpushhole_dias = [ 15, 18 ];
168 fingerpushhole_dias = [];
170 rearspeaker_pos_bl = [ 12.64, 18.72 ];
171 rearspeaker_size = [ 3.76, 7.36 ];
173 microusb_above = 3.27 - 0.25;
174 microusb_below = 0.0;
175 microusb_width = 16.12 + 1.25;
177 case_th_bottom = 2.5;
182 lid_screen_gap_extra = .66;
184 case_struts_count = 6;
185 case_struts_solid_below = 1.00;
186 case_struts_solid_above = 0.75;
187 case_struts_width = 0.10;
191 keeper_inner_width = 2.75;
192 keeper_inner_height = 2.75;
193 keeper_slant_slope = 2; // larger means steeper
195 keeper_gap_z_top = 0.25;
196 keeper_gap_z_bot = 0.75;
198 keeper_gap_x_holes = 0.75;
200 keeper_side = 0; // 0 = lhs; 1 = rhs
211 foldover_lever_gap = 0.50;
213 // properties of the hinge fasteners
214 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
215 hingescrew_shaft_len = 12;
216 hingescrew_fasteners_extra_thick = 0.40;
217 // ^ amount of thread protruding if everything was completely nominal
218 // and we are using two nuts
219 hingescrew_nut_access_dia = 4.72 + 0.50;
220 // ^ washer is 4.72 dia
221 // also, want to get pliers or tiny spanner in to do up locknut
222 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
223 hingescrew_nut_thick = 1.93;
224 hingescrew_head_th = 1.38 + 0.75;
225 hingescrew_head_dia = 3.92;
227 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
229 lever_cover_th = 0.75;
231 hingemount_wd = 4.8725;
236 button_l_fudge = 4.4;
237 buttonishleg_default_l_is_fudge = 10;
239 hinge_base_slope = 1.5; // bigger is steeper
241 strut_min_at_end = 1.5;
244 hinge_x_postscrew_gap = 0.75;
245 hinge_x_arms_gap = 0.35;
246 hinge_r_arms_gap = 0.55;
248 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
252 catch_thickness = 1.0;
253 catch_side_gap = 0.75; // each side
257 catch_finger_height = 1.5;
258 catch_finger_depth = 2.5;
260 prop_recess_under = 0.50;
261 prop_recess_slop = 0.200; // each side
266 prop_side_gap = 0.75; // each side
267 prop_lidrecess_behind = 0.75;
268 prop_caserecess_behind = 0.75;
269 prop_caserecess_taper = 0.45; // one side only
271 prop_prong_heel_slope = 0.5;
273 // ---------- calculated ----------
275 phone_width = (phone + bumper*2)[0];
276 phone_height = (phone + bumper*2)[1];
278 inside_br = [phone_width, -phone_height];
280 prop_prong_h = prop_main_th;
282 //echo(camera_pos_tl + bumper,
283 // camera_pos_br + bumper);
285 // ----- could be changed -----
286 lid_buttoncover_gap = lid_gap_x;
287 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
289 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
291 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
293 //prop_nose_len = case_th_lid - prop_recess_under;
294 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
295 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
298 //lid_lip_overlap_width xxx bad name = ;
299 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
302 epp1 = [0, -phone_edge_thick];
303 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
304 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
305 epp3 = epp2i + [10, 0];
306 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
307 epp4 = epp5 + [-1,0] * case_th_side;
310 kppd = kppe + [1,0] * keeper_inner_width;
311 kppc = kppd + [0,1] * keeper_th_z;
312 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
313 kppf = kppe - [0,1] * keeper_inner_height;
314 kppa = [ kppb[0], kppf[1] ];
316 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
317 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
319 lpp14 = lpp10 + [1,0] * keeper_inner_width;
320 // exact x posn not very important; must extend past end of keeper
323 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
324 + lid_screen_gap_extra ];
325 // ^ beam theory says to maximise force before contact,
326 // the gap below the `beam' (the lid) must be 1/3
327 // the thickness (ie the lid thickness) if the beam
328 // is solid, or 1/2 if it has a top and bottom only.
329 // ours is mostly solid.
331 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
334 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
335 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
337 case_bottom_z = epp2o[1] - case_th_bottom;
341 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
342 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
343 bppS = [ epp1[0], bppR[1] ];
344 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
345 bppP = bppQ + [0,1] * lid_buttoncover_gap;
346 bppO = [ bppN[0], bppP[1] ];
347 bppL = lpp10 + [5,0];
348 bppK = [ bppL[0], bppN[1] ];
349 bppJ = [ bppN[0], bppL[1] ];
350 bppU = [ bppJ[0], lpp12[1] ];
354 // notification led aperture
356 nla_r0 = led_aperture/2;
357 nla_r1 = nla_r0 + led_window_ledge;
358 nla_r2 = nla_r1 + multicolour_gap;
360 led_window_style >= 3 ? initial_layer_thick :
361 led_window_style >= 2 ? led_window_ledge : 0;
365 hp_rn = hingescrew_nut_access_dia/2;
366 hp_r2_min = hp_rn + lever_cover_th;
367 hp_rs = hingescrew_shaft_dia/2;
368 hp_r1_min = hp_rs + hingemount_th;
370 hp_r1 = max(hp_r1_min, hp_r2_min);
374 hppS = epp2o + [0,-1] * case_th_bottom;
375 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
377 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
378 0.5 * (hppU + hppS)[1] ];
379 hppT = [ hppM[0], hppU[1] - hp_r1 ];
380 hppB = hppT + [0,-1] * hp_k;
382 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
383 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
384 hppE = [ hppE_x, hppE_y ];
386 // hinge elevation x coords
388 hex20 = max(epp2o[0],
390 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
391 hex21 = hex20 + hingemount_wd;
392 hex22 = hex21 + hinge_x_gap;
393 hex27 = hex20 + hingescrew_shaft_len;
394 hex24 = hex27 + hinge_x_postscrew_gap;
395 hex23 = hex27 - (hingescrew_nut_thick*2
396 + hingescrew_fasteners_extra_thick);
397 hex26 = hex23 + hingescrew_nut_thick * 2/3;
399 echo(hex20, hex21, hex22, hex23, hex24);
400 // 6, 10.8725, 10.9975, 13.74, 18.75
401 module chk(act,exp) {
402 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
403 else echo("ok", act);
413 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
414 cppA = cppJ + [lid_gap_x, -lid_gap_z];
415 cppB = [ epp0[0], cppA[1] ];
416 cppP = [ epp4[0], cppJ[1] ];
418 cppS = cppJ + [0,-1] * catch_len;
419 cppD = [ cppA[0], cppS[1] + catch_slop ];
420 cppC = [ cppB[0], cppD[1] ];
421 cppT = cppS + [1,0] * catch_depth;
422 cppU = cppT + [0,-1] * catch_height;
423 cppV = [ cppS[0], cppU[1] - catch_depth ];
425 cppR = 0.5*(cppP + cppJ);
427 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
429 cppV[1] - (catch_finger_height - cp_rQ) ];
430 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
432 // prop recess in case
434 prop_x_pos = phone_width/2;
436 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
438 prc_r1 = prop_end_dia/2;
439 prc_r3 = prc_r1 + prop_recess_slop;
441 prcp2 = [ epp4[0] + prop_buildout_less,
444 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
446 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
447 epp2i[1] - prc_r3 - prop_recess_under];
449 // prop recess in lid
451 prl_r10 = prop_end_dia/2;
452 prl_r10o = prl_r10 + prop_recess_slop;
454 prlp10 = lpp10 + [1,1] * prl_r10o
455 + [1,0] * prop_lidrecess_behind
456 + [0,1] * prop_recess_under;
461 $prpp11 = [0, prop_taper_len];
465 // ---------- modules ----------
467 module AdhocMultiprintFrame(phase, z0, zs) {
468 // from z0 to z0 + zs*layer
469 extra = phase * (initial_layer_width + multicolour_gap) + 5;
470 xextra = extra + -epp4[0];
471 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
472 yextra = extra + -epp4[0];
473 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
474 p0 = [ xrange[0], yrange[0] ];
475 p1 = [ xrange[1], yrange[1] ];
478 mirror([0,0, zs<0 ? 1 : 0])
479 linear_extrude(height= initial_layer_thick)
481 rectfromto(p0 - [1,1] * initial_layer_width,
482 p1 + [1,1] * initial_layer_width);
487 module KeeperProfile(slant=0){
488 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
489 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
492 module EdgeProfile(){
495 translate(epp3) square(case_th_bottom*2, center=true);
496 circleat(epp2o, r=case_th_bottom);
497 circleat(epp1, r=case_th_side);
498 rectfromto(epp0, epp4);
500 polygon([ epp5 + [0,10],
507 module LidEdgeProfile(){
518 circleat(lpp12, r=lp_r12);
519 rectfromto( lpp12 + [-10, 0],
520 lpp12 + [+10, +10] );
524 module LidEdgeFoldClearanceProfile(){
533 module ButtonCoverProfile(){
535 polygon(concat([ bppM, bppP, bppO, bppJ ],
536 (enable_support && !$button_suppress_over_keeper
537 ? [ bppU, bppV, bppW ] : []),
546 module ButtonPlan(l, deep, cut){
548 (cut ? 0 : lid_buttoncover_gap);
551 (deep ? lid_buttoncover_overlap : 0);
553 C = [0,0]; // by definition
557 B0 = C + [0,-1] * button_cutout_depth;
558 B1 = B0 + [0,1] * epsilon;
560 r0 = 0.5 * (T[1] - B0[1]);
561 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
562 H = A + [0,-1] * delta;
568 E1 = E0 + [1,0] * epsilon;
570 I0 = [ E0[0], H[1] ];
571 I1 = [ E1[0], H[1] ];
574 for (m=[0,1]) mirror([m,0])
575 circleat(H, r0 - epsilon);
577 for (m=[0,1]) mirror([m,0]) {
587 circleat(D, r0 + epsilon);
592 module CatchCatchProfile(){
594 for (c=[ cppR, cppQ ])
598 circleat(lpp12, lp_r12);
599 circleat(lpp12 + [5,0], lp_r12);
600 rectfromto(cppP, cppP + [5,0.1]);
602 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
605 module CatchCutProfile(){
617 module Flip_rhs(yn=[0,1]) {
619 translate([phone_width/2, 0, 0])
620 mirror([$rhsflip,0,0])
621 translate([-phone_width/2, 0, 0])
626 module Flip_bot(yn=[0,1]) {
628 translate([0, -phone_height/2, 0])
629 mirror([0, $botflip, 0])
630 translate([0, phone_height/2, 0])
635 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
638 translate([0, -phone_cnr_rad, 0])
640 linear_extrude(height = phone_height - phone_cnr_rad*2)
644 Flip_rhs() Flip_bot() {
645 translate([+1,-1] * phone_cnr_rad)
650 translate([-1,0] * phone_cnr_rad)
652 rectfromto([0,-20],[10,20]);
654 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
660 translate([ phone_width - phone_cnr_rad, 0,0 ])
662 linear_extrude(height = phone_width - phone_cnr_rad*2)
666 translate([0,0, fill_zstart])
667 mirror([0,0, fill_downwards])
668 linear_extrude(height = fill_th)
669 rectfromto([+1,-1] * phone_cnr_rad,
670 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
673 module CaseAperture(pos, dia, $fn) {
675 translate([ pos[0] + bumper[0],
678 rotate([-90, theta, 0])
679 cylinder(r = dia/2 / cos(theta),
683 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
685 // +1 measured from top of actual phone to top of button
686 // -1 measured from bottom of actual phone to bottom of button
687 // 0 y is centre of button in coordinate system
689 $button_suppress_over_keeper= suppress_over_keeper;
690 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
691 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
694 translate([0, eff_y, 0])
698 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
699 $button_leg_only = true;
700 SideButton(y, y_ref_sign, l) children();
704 Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
705 Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
706 Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
707 Flip_rhs( ) LidButtonishLeg(14, -1) children();
708 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
711 module Struts(x_start, z_min, th){
712 // if th is negative, starts at z_min and works towards -ve z
713 // and object should then be printed other way up
714 for (i= [1 : 1 : case_struts_count]) {
718 mirror([0,0, th<0 ? 1 : 0])
720 -phone_height * i / (case_struts_count+1),
721 case_struts_solid_below])
722 linear_extrude(height= abs(th)
723 -(case_struts_solid_below+case_struts_solid_above))
724 rectfromto([ x_start, -0.5 * case_struts_width ],
725 [ phone_width - x_start, +0.5 * case_struts_width ]);
729 module OrdinaryRearAperture(rhs,bot, pos){
730 Flip_rhs(rhs) Flip_bot(bot)
733 translate(pos + bumper)
741 linextr(-epp2i[0], 60)
742 translate([0.5 * phone_width, 0, 0])
743 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
744 [+microusb_width/2, epp0[1] + -microusb_above]);
748 module OrdinaryRearApertures(){
750 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
751 rectfromto(-rearspeaker_gap,
752 rearspeaker_size + rearspeaker_gap);
754 // finger hole to remove phone
755 if (len(fingerpushhole_dias))
756 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
758 scale(fingerpushhole_dias)
762 module RearCameraAperture(){
765 linear_extrude(height = 20)
768 rectfromto(camera_pos_tl, camera_pos_br);
771 module HingeLidProfile(){
773 circleat(hppT, hp_r1);
774 circleat(lpp12, lp_r12);
782 module HingeBaseProfile(){
785 circleat(hppB, hp_r1);
786 circleat(hppE, hp_r1);
787 circleat(epp2o, case_th_bottom);
788 circleat(hppB + [10,0], hp_r1);
790 polygon([epp5, epp1, epp2i, epp3, bppL]);
794 module HingeLeverOuterProfile(){
796 circleat(hppT, hp_r2);
797 circleat(hppB, hp_r2);
801 module HingeLeverInnerProfile(){
803 c = s > 0 ? hppT : hppB;
806 rotate(s<0 ? -40 : 0)
815 module HingeLeverNutProfile(){
816 for (c= [hppB, hppT]) {
818 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
822 module Flip_hinge(doflip=1){
823 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
824 translate(hinge_origin)
825 rotate([doflip*180,0,0])
826 translate(-hinge_origin)
830 module HingePortion(x0,x1){
831 Flip_rhs() Flip_bot(1)
835 linear_extrude(height=x1-x0)
839 module CatchPortion(width){
840 translate([phone_width/2, 0,0])
842 linextr(-width/2, width/2)
847 AroundEdges(epp3[1], case_th_bottom, 1)
851 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
853 module PropProfileAssignments(gamma){
854 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
856 p = phone_height + prlp10[0] - hppB[0];
859 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
861 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
862 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
864 $prp_theta = 90 - $prp_alpha;
865 beta = 180 - $prp_alpha - gamma;
868 //echo("abc", a,b,c);
870 v1 = [ [ cos(psi), -sin(psi) ], // x
871 [ sin(psi), cos(psi) ] ]; // y
873 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
876 $prp_r11 = prop_main_th/2;
878 $prpp1 = $prpp7 + [1,0] *
879 // this is approximate, but will do
880 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
883 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
884 $prpp12 = $prpp3 + v1[0] *
885 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
886 $prp_r8 = prop_main_th;
887 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
889 $prpp5 = [ $prpp12[0] - $prp_r5,
890 $prpp3[1] - prop_prong_h + $prp_r5 ];
891 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
892 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
893 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
894 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
899 module PropProfile(gamma, cut=0, rot=0){ ////toplevel
900 PropProfileAssignments(gamma){
902 //#circleat($prpp3,1);
903 //#circleat($prpp12,1);
910 polygon([[-20,-0], [20,20], [0,0]]);
912 rectfromto($prpp6, $prpp9);
913 translate($prpp5) intersection(){
915 polygon([[-10,-10], [0,0], [10,0]]);
917 rectfromto($prpp12 + [0,-0.1], $prpp3);
920 circleat($prpp1, $prp_r1);
921 rectfromto($prpp12 + [0,-0.1], $prpp3);
925 rotate([0,0, rot*-$prp_theta]){
927 extra = cut ? prop_recess_slop : 0;
928 rectfromto($prpp6, $prpp9);
929 circleat($prpp11, $prp_r11 + extra);
930 circleat($prpp10, $prp_r10 + extra);
936 module PropAggregateProfile(){
937 for (angle = prop_angles)
938 PropProfile(angle, 0,0);
941 module Prop(){ ////toplevel
942 hw = prop_main_width/2;
944 PropAggregateProfile();
947 module Case(){ ////toplevel
952 // ledge (fixed keeper)
953 Flip_rhs(1-keeper_side) intersection(){
955 linear_extrude(height = phone_height + phone_cnr_rad * 2)
958 // outline of the whole case, to stop it protruding
959 translate([0,0, -25])
960 linear_extrude(height = 50)
963 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
967 HingePortion(hex20, hex21) HingeBaseProfile();
969 // buildout for prop recess
970 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
971 linextr(case_bottom_z, epp2i[1])
974 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
976 r = epp2o[0] - prcp2[0]);
981 Flip_rhs(keeper_side)
982 translate([0, -phone_cnr_rad, 0])
984 linear_extrude(height = phone_height + phone_cnr_rad * 2)
987 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
988 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
992 RearCameraAperture();
994 // struts (invisible, because they're buried in the case)
995 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1000 if (!($button_leg_only && enable_support))
1002 translate([0,0,-10])
1003 linear_extrude(height= 20)
1004 ButtonPlan($button_l, 0,1);
1005 if ($button_leg_only)
1007 translate([phone_width/2, -400, kppe[1]])
1008 mirror([1-abs($rhsflip - keeper_side),0,0])
1009 cube([400, 800, 50]);
1010 if (enable_support && !$button_suppress_over_keeper)
1012 translate([-400, -400, kppd[1]])
1014 cube([800,800,100]);
1016 translate([0,0, -bppR[0]])
1017 linear_extrude(height= 20)
1018 ButtonPlan($button_l, 1,1);
1023 // apertures along top edge
1024 CaseAperture(jack_pos, jack_dia, 8);
1026 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1028 OrdinaryRearApertures();
1032 // gaps for the lid's hinge arms
1033 HingePortion(hex20 - hinge_x_arms_gap,
1034 hex21 + hinge_x_arms_gap)
1037 circle(r= hinge_r_arms_gap, $fn= 8);
1040 // screw holes in the hinge arms
1044 CatchPortion(catch_width + catch_side_gap*2)
1049 translate([prop_x_pos,0,0])
1052 linextr(-prop_recess_hw, +prop_recess_hw)
1054 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1055 circleat(prcp1 + 20*d,
1061 module LidAdhocMultiprintFrame(phase){
1062 if (led_window_style >= 3) {
1063 AdhocMultiprintFrame(phase, lpp13[1], -1);
1067 module LidAroundEdges(){
1068 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
1072 module Lid(){ ////toplevel
1073 skew_centre = [0, lpp11[0], lpp11[1]];
1080 translate(skew_centre)
1081 multmatrix([[ 1, 0, 0, 0 ],
1085 translate(-skew_centre)
1087 LidEdgeFoldClearanceProfile();
1094 translate([0,0,-10])
1095 linear_extrude(height= 20)
1096 ButtonPlan($button_l, 1,0);
1098 translate([0,0,-100])
1099 linear_extrude(height= 200)
1100 ButtonCoverProfile();
1105 HingePortion(hex20, hex21) HingeLidProfile();
1108 CatchPortion(catch_width)
1109 CatchCatchProfile();
1111 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1113 // screw holes in the hinge arms
1117 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1120 linextr(-prop_recess_hw, +prop_recess_hw)
1122 for (pa = prop_angles)
1123 PropProfile(pa, 1,1);
1125 // notification led aperture
1126 if (led_window_style)
1127 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1128 translate([0,0,-10])
1129 cylinder(r=nla_r0, h=20);
1130 if (led_window_style >= 2)
1131 translate([0,0, -nla_t])
1132 cylinder(r=nla_r2, height=20);
1137 LidAdhocMultiprintFrame(1);
1140 module HingeLever(){ ////toplevel
1142 // outer body, positive
1143 HingePortion(hex22, hex22 + phone_width/2)
1144 HingeLeverOuterProfile();
1146 // space for the screws
1147 HingePortion(hex26, hex24)
1148 HingeLeverInnerProfile();
1150 // recesses for the nuts
1151 HingePortion(hex23, hex26+1)
1152 HingeLeverNutProfile();
1154 // bores for the screws
1157 // space for the charging cable
1159 Flip_hinge() MicroUSB();
1163 module LidWindow(){ ////toplevel
1164 translate([led_pos[0], -led_pos[1], lpp13[1]])
1166 cylinder(r= nla_r1, h=nla_t);
1167 LidAdhocMultiprintFrame(0);
1170 module LidWindowPrint(){ ////toplevel
1175 module DemoLidWindowSelect(){
1176 translate([led_pos[0], led_pos[1], -100]) {
1177 translate([0, -30, 0]) cube([400, 400, 200]);
1181 module DemoLidWindow(){ ////toplevel
1184 translate([0,40,0]){
1185 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1186 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1190 module HingeLeverPrint(){ ////toplevel
1192 translate([-phone_width/2, phone_height, 0])
1196 module TestSelectLength(){
1197 translate([-30, -200, -20])
1198 cube([30 + 15, 250, 40]);
1201 module TestLength(){ ////toplevel
1208 module TestLengthRight(){ ////toplevel
1216 module TestSelectWidth(){
1217 translate([-30, -(phone_height - 25), -20])
1219 cube([200, 50, 40]);
1222 module TestWidth(){ ////toplevel
1229 module TestLidWidthPrint(){ ////toplevel
1230 rotate([0,180.0]) intersection(){
1236 module TestSelectRearAperture(){
1239 translate([20, 0,0])
1240 cube([42, 2, 1], center=true);
1244 module TestSelectCamera(){
1246 TestSelectRearAperture()
1247 RearCameraAperture();
1248 cube([0.1, 50, 0.1]);
1252 module TestSelectOrdinaryRearApertures(){
1253 TestSelectRearAperture()
1254 OrdinaryRearApertures();
1257 module TestCamera(){ ////toplevel
1264 module TestLidByCamera(){ ////toplevel
1271 module TestLidByCameraPrint(){ ////toplevel
1272 rotate([180,0,0]) TestLidByCamera();
1275 module DemoByCamera(){ ////toplevel
1276 color("blue") TestLidByCamera();
1277 color("red") TestCamera();
1280 module OneKeeper(){ ////toplevel
1281 translate([0, -phone_cnr_rad, 0])
1283 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1287 module OneKeeperPrint(){ ////toplevel
1292 module LidPrint(){ ////toplevel
1297 module TestSelectFrame(){
1298 include = [1,-1] * (epp2i[0] + 4);
1301 cube(1000, center=true);
1302 translate([0,0, -100])
1303 linear_extrude(height=200)
1304 rectfromto(include, inside_br - include);
1308 module TestSelectLidFrame(){
1310 translate([led_pos[0], -led_pos[1], -50])
1311 cylinder(r= nla_r2+3, h=100);
1314 module TestFrameCase(){ ////toplevel
1320 TestSelectOrdinaryRearApertures();
1325 module TestSelectTopApertures(){
1326 translate([-100, -35, -100])
1327 cube([400, 100, 200]);
1328 LidAdhocMultiprintFrame(0);
1329 LidAdhocMultiprintFrame(1);
1332 module TestTopApertures(){ ////toplevel
1336 TestSelectTopApertures();
1340 module TestLidTopAperturesPrint(){ ////toplevel
1341 rotate([0,180,0]) intersection(){
1343 TestSelectLidFrame();
1344 TestSelectTopApertures();
1348 module TestLidWindowTopAperturesPrint(){ ////toplevel
1349 rotate([0,180,0]) intersection(){
1351 TestSelectTopApertures();
1355 module TestFrameLidPrint(){ ////toplevel
1356 rotate([0,180,0]) intersection(){
1358 TestSelectLidFrame();
1362 module ButtonPlanForDemo(z, deep, cut){
1364 ButtonPlan(8, deep, cut);
1367 module HingeScrews(){
1368 Flip_rhs() Flip_bot(1){
1369 for (c= [ hppT, hppB ])
1374 translate([0,0,-.2])
1375 cylinder( r= hingescrew_shaft_dia/2,
1376 h = hingescrew_shaft_len+0.2 );
1378 translate([0,0,+.1])
1379 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1384 module DemoPropAngleSelect(c){
1385 color(c) difference(){
1386 union(){ children(); }
1387 translate([ prop_x_pos, -400, -200 ])
1388 cube([ 400,800,400 ]);
1392 module DemoPropAngle(ang){
1393 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1394 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1402 DemoPropAngleSelect("red") Case();
1405 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1406 PropProfileAssignments(ang) {
1408 rotate([-$prp_theta, 0, 0])
1409 translate([0, $prpp1[0], -$prpp1[1]])
1415 translate([0,0, -hp_k*2])
1416 DemoPropAngleSelect("blue")
1420 module DemoPropAngles(){ ////toplevel
1421 for (i=[0 : len(prop_angles)-1])
1422 translate(i * [0, -100, 100])
1423 DemoPropAngle(prop_angles[i]);
1426 module DemoHingeAngle(ang1,ang2){
1427 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1428 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1439 color("blue") intersection(){
1442 translate([bppJ[0], -400, -200])
1444 cube([400, 800, 400]);
1445 translate([10, -400, -200])
1446 cube([10, 800, 400]);
1451 module DemoHingeAngles(){ ////toplevel
1452 angles = [ 0, 4, 8, 12 ];
1453 echo("angles",angles);
1454 for (i=[0 : len(angles)-1]) {
1455 translate(i * [0, 0, 30]) {
1456 DemoHingeAngle(0,angles[i]);
1457 translate([0, 200, 0])
1458 DemoHingeAngle(angles[i],0);
1463 module DemoSelectAdhocLeftRight(right=0) {
1464 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1465 mirror([1-right, 0,0])
1466 cube([400, 800, 200]);
1469 module DemoLeft(){ ////toplevel
1470 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1471 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1474 module DemoFrame(){ ////toplevel
1475 color("red") TestFrameCase();
1476 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1477 color("black") HingeScrews();
1481 module DemoHingedFrame(){ ///toplevel
1482 color("red") TestFrameCase();
1483 translate([0,0, -2*hp_k])
1484 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1487 color("orange") HingeLever();
1488 color("black") HingeScrews();
1492 module DemoHinge(){ ////toplevel
1493 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1495 translate([0,0, -hp_k*3])
1500 module DemoProfiles(){ ////toplevel
1504 translate([0,0,-1]) color("black") KeeperProfile(1);
1510 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1512 color("blue") ButtonCoverProfile();
1514 rectfromto(bppQ, demopoint_QR);
1515 rectfromto(bppR, demopoint_QR);
1519 translate([-20,0]) {
1520 color("black") ButtonPlanForDemo(-2, 0,1);
1521 color("red" ) ButtonPlanForDemo(-4, 1,1);
1522 color("blue") ButtonPlanForDemo(-6, 1,0);
1525 translate([0, -30]) {
1528 color("blue") HingeLidProfile();
1529 color("red") HingeBaseProfile();
1530 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1534 translate([-30, -60 + 30*f]) {
1535 translate([0,0,-4]) EdgeProfile();
1536 %translate([0,0,-10]) HingeBaseProfile();
1537 translate([0,-2] * f * hp_k) {
1538 translate([0,0,-4]) LidEdgeProfile();
1539 %translate([0,0,-10]) %HingeLidProfile();
1541 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1542 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1543 translate([0,0,0]) color("red") difference(){
1544 HingeLeverOuterProfile();
1545 HingeLeverInnerProfile();
1547 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1552 translate([20,-30]) {
1555 //translate([0,0,1]) CatchCutProfile();
1556 color("blue") CatchCatchProfile();
1557 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
1560 translate([40,-30]) {
1564 PropProfile(10, 1, 0);
1569 translate([60,-30]) {
1570 PropAggregateProfile();