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.
123 phone = [ 75.86, 162.0 ];
125 prop_buildout_less = 3;
127 prop_angles = [ 15, 30, 45, 60 ];
129 bumper = [ 0.250, -0.025 ];
130 // ^ One side. Overall size is increased by twice this.
131 // If no bumpers, is the gap around the phone.
135 led_window_style = 0;
137 // 1: simply an opening
138 // 2: opening with separate cover model, for printing in clear (two colour)
139 // 3: like 2 but one-layer window for ad-hoc multi-colour
141 initial_layer_thick = 0.400; // ^ needed for mode 3 only
142 initial_layer_width = 0.750; // ^ needed for mode 3 only
143 multicolour_gap = 0.15; // each side
145 phone_cnr_rad = 7.0; // actuall 8.mumble, but smaller is fine
146 phone_rim_depth = 0.01; // includes allowance for a screen protector
148 button_cutout_depth = 9;
150 phone_edge_thick = 11.25;
152 camera_pos_tl = [ 5.600, 5.750 ]; // from tl corner (as seen from back)
153 camera_edge_rad = 9.750 + 0.700;
154 camera_sz = 32.920 + .750 + 1.000;
156 // this is disabled, FP4 doesn't have one
157 jack_pos = [ 13.83, 8.485 ];
158 jack_dia = 10.64 + .5; // some jack I had lying around
160 // this led stuff, is irrelevant, we have disabled it as it doesn't have one
161 led_pos = []; // [ 13.98, 10.00 ];
163 led_window_ledge = 0.75; // each side
165 noisecancelmic_pos = [ 15.08 + .720, 4.35 ]; // from rhs, from top edge
166 noisecancelmic_dia = 4.00;
168 mainmic_pos = [ 21.0, 4.65 ]; // from lhs, from top edge
171 lhshole_pos = [ phone[1]/2 + 0.40, 4.35 ];
173 // fingerpushhole_dias = [];
174 fingerpushhole_dias = [ 15, 18 ]; // this is for testing
176 lanyard_half_dia = 1.15;
177 lanyard_entry_rel_breadth = 2;
178 lanyard_channel_len = 8;
179 //rearspeaker_pos_bl = [ 12.64, 18.72 ];
180 //rearspeaker_size = [ 3.76, 7.36 ];
182 bottomspeaker_size = [ 11.35, 1.90 ] + [1,1] * 0.5;
183 bottomspeaker_pos = [ 17.55, 5.17 ]; // from rhs, from top
185 microusb_above = 1.64 - 0.25;
186 microusb_below = 2.42;
187 microusb_width = 12.16 + 2.0 + 1.25;
189 case_th_bottom = 2.5;
194 lid_screen_gap_extra = .66;
196 case_struts_count = 6;
197 case_struts_solid_below = 1.00;
198 case_struts_solid_above = 0.75;
199 case_struts_width = 0.10;
203 keeper_inner_width = 2.75;
204 keeper_inner_height = 2.75;
205 keeper_slant_slope = 2; // larger means steeper
207 keeper_gap_z_top = 0.25;
208 keeper_gap_z_bot = 0.75;
210 keeper_gap_x_holes = 0.75;
211 keeper_fatter = 0.45;
212 keeper_fatter_hole = 1.20;
214 keeper_side = 0; // 0 = lhs; 1 = rhs
221 lid_edgepart_width = 5.0;
222 lid_buttoncover_thick = 1.3;
223 lid_buttoncover_reinf = 0.65;
226 foldover_lever_gap = 0.50;
228 // properties of the hinge fasteners
229 hingescrew_shaft_dia = 1.600 + 0.45; // beading wire
230 hingescrew_shaft_len = 10;
231 hingescrew_fasteners_extra_thick = 0.40;
232 // ^ amount of thread protruding if everything was completely nominal
233 // and we are using two nuts
234 hingescrew_nut_access_dia = 4.72 + 0.50;
235 // ^ washer is 4.72 dia
236 // also, want to get pliers or tiny spanner in to do up locknut
237 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
238 hingescrew_nut_thick = 1.93;
239 hingescrew_head_th = 1.38 + 0.75;
240 hingescrew_head_dia = 3.92;
242 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
244 lever_cover_th = 0.75;
246 hingemount_wd = 4.8725;
251 button_l_fudge = 4.4;
252 buttonishleg_default_l_is_fudge = 10;
254 hinge_base_slope = 1.5; // bigger is steeper
256 strut_min_at_end = 1.5;
259 hinge_x_postscrew_gap = 0.75;
260 hinge_x_arms_gap = 0.35;
261 hinge_r_arms_gap = 0.55;
262 hinge_over_nut_plate = -0.50; // bodge apropos slope
264 // there isn't one of these, speaker is by hinge
265 // rearspeaker_gap = [ 2.0, 2.0 ]; // each side
267 thumbrecess_depth = 1.3;
268 thumbrecess_width = 16.5;
269 thumbrecess_topcurve_r = 5.0;
271 prop_recess_under = 0.50;
272 prop_recess_slop = 0.200; // each side
277 prop_side_gap = 0.75; // each side
278 prop_lidrecess_behind = 0.75;
279 prop_caserecess_behind = 0.75;
280 prop_caserecess_taper = 0.45; // one side only
282 prop_prong_heel_slope = 0.5;
284 lid_fold_clearance_antislop = 0.5;
286 $button_leg_only = false;
287 $suppress_forward_holes = false;
289 // ---------- calculated ----------
291 phone_total_thick = phone_edge_thick;
293 phone_width = (phone + bumper*2)[0];
294 phone_height = (phone + bumper*2)[1];
296 inside_br = [phone_width, -phone_height];
298 prop_prong_h = prop_main_th;
300 //echo(camera_pos_tl + bumper,
301 // camera_pos_br + bumper);
303 // ----- could be changed -----
304 lid_buttoncover_gap = lid_gap_x;
305 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
307 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
309 //prop_nose_len = case_th_lid - prop_recess_under;
310 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
311 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
315 epp1 = [0, -phone_edge_thick];
316 epp2i = epp1; // conflated for FP4
318 epp3 = epp2i + [10, 0];
319 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
320 epp4 = epp5 + [-1,0] * case_th_side;
323 kppd = kppe + [1,0] * keeper_inner_width;
324 kppc = kppd + [0,1] * keeper_th_z;
325 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
326 kppf = kppe - [0,1] * keeper_inner_height;
327 kppa = [ kppb[0], kppf[1] ];
329 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
330 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
332 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
333 // exact x posn not very important; must extend past end of keeper
336 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
337 + lid_screen_gap_extra ];
338 // ^ beam theory says to maximise force before contact,
339 // the gap below the `beam' (the lid) must be 1/3
340 // the thickness (ie the lid thickness) if the beam
341 // is solid, or 1/2 if it has a top and bottom only.
342 // ours is mostly solid.
344 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
347 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
348 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
350 case_bottom_z = epp2o[1] - case_th_bottom;
354 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
355 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
356 bppS = [ epp1[0], bppR[1] ];
357 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
358 bppP = bppQ + [0,1] * lid_buttoncover_gap;
359 bppO = [ bppN[0], bppP[1] ];
360 bppL = lpp10 + [5,0];
361 bppK = [ bppL[0], bppN[1] ];
362 bppJ = [ bppN[0], bppL[1] ];
363 bppU = [ bppJ[0], lpp12[1] ];
367 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
369 // notification led aperture
371 nla_r0 = led_aperture/2;
372 nla_r1 = nla_r0 + led_window_ledge;
373 nla_r2 = nla_r1 + multicolour_gap;
375 led_window_style >= 3 ? initial_layer_thick :
376 led_window_style >= 2 ? led_window_ledge : 0;
380 hp_rn = hingescrew_nut_access_dia/2;
381 hp_r2_min = hp_rn + lever_cover_th;
382 hp_rs = hingescrew_shaft_dia/2;
383 hp_r1_min = hp_rs + hingemount_th;
385 hp_r1 = max(hp_r1_min, hp_r2_min);
389 hppS = epp2o + [0,-1] * case_th_bottom;
390 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
392 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
393 0.5 * (hppU + hppS)[1] ];
394 hppT = [ hppM[0], hppU[1] - hp_r1 ];
395 hppB = hppT + [0,-1] * hp_k;
397 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
398 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
399 hppE = [ hppE_x, hppE_y ];
401 // hinge elevation x coords
403 hex20 = max(epp2o[0],
405 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
406 hex21 = hex20 + hingemount_wd;
407 hex22 = hex21 + hinge_x_gap;
408 hex27 = hex20 + hingescrew_shaft_len;
409 hex24 = hex27 + hinge_x_postscrew_gap;
410 hex23 = hex27 - (hingescrew_nut_thick*2
411 + hingescrew_fasteners_extra_thick);
412 hex26 = hex23 + hingescrew_nut_thick * 2/3;
414 //echo(hex20, hex21, hex22, hex23, hex24);
415 //// 6, 10.8725, 10.9975, 13.74, 18.75
416 //module chk(act,exp) {
417 // if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
418 // else echo("ok", act);
421 //chk(hex21, 10.8725);
422 //chk(hex22, 10.9975);
426 lid_fold_clearance_skew =
427 (lpp10[1] - hppB[1]) /
428 (lpp10[0] - hppB[0]);
430 echo("SK",lid_fold_clearance_skew);
432 // thumb recess (used to be "catch" hence cpp*
434 cppA = epp4 + [thumbrecess_depth, 0];
435 cppB = [ cppA[0], epp1[1] ];
439 ly_r = lanyard_half_dia / 2;
443 ly_o = epp2i + 3 * ly_r * [0,1];
445 max_case_bottom_edge_thickness =
448 ly_q_z = -(ly_rc + ly_r);
449 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
451 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
453 // prop recess in case
455 prop_x_pos = phone_width/2;
457 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
459 prc_r1 = prop_end_dia/2;
460 prc_r3 = prc_r1 + prop_recess_slop;
462 prcp2 = [ epp4[0] + prop_buildout_less,
465 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
467 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
468 epp2i[1] - prc_r3 - prop_recess_under];
470 // prop recess in lid
472 prl_r10 = prop_end_dia/2;
473 prl_r10o = prl_r10 + prop_recess_slop;
475 prlp10 = lpp10 + [1,1] * prl_r10o
476 + [1,0] * prop_lidrecess_behind
477 + [0,1] * prop_recess_under;
482 $prpp11 = [0, prop_taper_len];
486 // ---------- modules ----------
488 module AdhocMultiprintFrame(phase, z0, zs) {
489 // from z0 to z0 + zs*layer
490 extra = phase * (initial_layer_width + multicolour_gap) + 5;
491 xextra = extra + -epp4[0];
492 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
493 yextra = extra + -epp4[0];
494 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
495 p0 = [ xrange[0], yrange[0] ];
496 p1 = [ xrange[1], yrange[1] ];
499 mirror([0,0, zs<0 ? 1 : 0])
500 linear_extrude(height= initial_layer_thick)
502 rectfromto(p0 - [1,1] * initial_layer_width,
503 p1 + [1,1] * initial_layer_width);
508 module KeeperProfile(fatter, slant=0){
509 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
510 polygon([use_e + [+1,-1] * fatter,
511 kppd + [ 0,-1] * fatter,
515 kppf + [+1, 0] * fatter
519 module EdgeProfile(){
522 translate(epp3) square(case_th_bottom*2, center=true);
523 circleat(epp2o, r=case_th_bottom);
524 circleat(epp1, r=case_th_side);
525 rectfromto(epp0, epp4);
527 polygon([ epp5 + [0,10],
533 module LanyardLanyardProfile(entry=false){
535 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
536 translate(xs * 0.5 * lanyard_half_dia * [1,0])
537 circle(r= lanyard_half_dia/2);
541 module LanyardCurveChannelProfile(){
542 translate([0, -ly_r])
543 LanyardLanyardProfile();
546 module LanyardEntryChannelProfile(){
547 LanyardLanyardProfile(true);
550 module LanyardMainChannelProfile(){
551 LanyardCurveChannelProfile();
553 square(center=true, ly_r * [6, 2]);
555 translate(ly_r * [3 * xs, -1])
560 module LanyardEntryOuterProfile(){
561 circleat([ly_re + ly_r, 0], ly_re);
564 module LanyardEntry(){
570 translate([d_x, 0, q_z]) {
573 rotate_extrude(convexity=10)
576 LanyardCurveChannelProfile();
584 linear_extrude(height=20)
586 LanyardEntryChannelProfile();
588 translate([0, ly_r*2, 0])
590 linear_extrude(height = ly_r*4){
592 rectfromto([d_x, q_z], [ly_r, 0]);
593 circleat([d_x, q_z], ly_rc);
597 translate([0,0,q_z]){
600 translate([0, oec_y, 0]){
602 translate(ly_re * [-1,0,-2])
603 cube(ly_re * [2,1,2]);
604 rotate_extrude(convexity=10)
605 LanyardEntryOuterProfile();
610 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
611 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
616 linear_extrude(height=20)
617 LanyardEntryOuterProfile();
622 module LanyardCutout(l){
624 linear_extrude(height=l)
626 LanyardMainChannelProfile();
629 translate(ee * l * [-1,0])
635 module LidEdgeProfile(){
646 circleat(lpp12, r=lp_r12);
647 rectfromto( lpp12 + [-10, 0],
648 lpp12 + [+10, +10] );
652 module LidEdgeFoldClearanceProfile(){
653 translate([-lid_fold_clearance_antislop, 0])
662 module ButtonCoverProfile(){
664 polygon(concat([ bppM, bppP, bppO, bppJ ],
665 (enable_support && !$button_suppress_over_keeper
666 ? [ bppU, bppV, bppW ] : []),
675 module ButtonPlan(l, deep, cut){
677 (cut ? 0 : lid_buttoncover_gap);
680 (deep ? lid_buttoncover_overlap : 0);
682 C = [0,0]; // by definition
686 B0 = C + [0,-1] * button_cutout_depth;
687 B1 = B0 + [0,1] * epsilon;
689 r0 = 0.5 * (T[1] - B0[1]);
690 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
691 H = A + [0,-1] * delta;
697 E1 = E0 + [1,0] * epsilon;
699 I0 = [ E0[0], H[1] ];
700 I1 = [ E1[0], H[1] ];
703 for (m=[0,1]) mirror([m,0])
704 circleat(H, r0 - epsilon);
706 for (m=[0,1]) mirror([m,0]) {
716 circleat(D, r0 + epsilon);
721 module ButtonCoverReinf(){ ////toplevel
724 linear_extrude(height=0.01)
726 ButtonCoverProfile();
727 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
730 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
731 circle(r= lid_buttoncover_reinf);
732 translate([-20,0]) square(40, center=true);
737 module ThumbRecessCutProfile(){
739 polygon([ cppA + [-10,0],
743 circleat(epp1, r=case_th_side);
747 module Flip_rhs(yn=[0,1]) {
749 translate([phone_width/2, 0, 0])
750 mirror([$rhsflip,0,0])
751 translate([-phone_width/2, 0, 0])
756 module Flip_bot(yn=[0,1]) {
758 translate([0, -phone_height/2, 0])
759 mirror([0, $botflip, 0])
760 translate([0, phone_height/2, 0])
765 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
768 translate([0, -phone_cnr_rad, 0])
770 linear_extrude(height = phone_height - phone_cnr_rad*2)
774 Flip_rhs() Flip_bot() {
775 translate([+1,-1] * phone_cnr_rad)
780 translate([-1,0] * phone_cnr_rad)
782 rectfromto([0,-20],[10,20]);
784 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
790 translate([ phone_width - phone_cnr_rad, 0,0 ])
792 linear_extrude(height = phone_width - phone_cnr_rad*2)
796 translate([0,0, fill_zstart])
797 mirror([0,0, fill_downwards])
798 linear_extrude(height = fill_th)
799 rectfromto([+1,-1] * phone_cnr_rad,
800 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
803 module CaseAperture(pos, dia, $fn, topbottom=0) {
805 translate([ bumper[0],
808 rotate([0,0, 90*topbottom])
809 translate([ pos[0] * (topbottom>0 ? -1 : +1), 0, -pos[1] ])
810 rotate([-90, theta, 0])
811 cylinder(r = dia/2 / cos(theta),
815 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
817 // +1 measured from top of actual phone to top of button
818 // -1 measured from bottom of actual phone to bottom of button
819 // 0 y is centre of button in coordinate system
821 $button_suppress_over_keeper= suppress_over_keeper;
822 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
823 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
826 translate([0, eff_y, 0])
830 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
831 $button_leg_only = true;
832 SideButton(y, y_ref_sign, l) children();
836 Flip_rhs(1) SideButton(30.320, +1, 22.960 ) children(); // volume
837 Flip_rhs(1) SideButton(64.220, +1, 14.500 ) children(); // power
838 Flip_rhs(1) LidButtonishLeg(14, -1) children();
839 Flip_rhs(0) LidButtonishLeg(21, -1) children();
840 Flip_rhs(0) LidButtonishLeg(21, +1) children();
843 module Struts(x_start, z_min, th){
844 // if th is negative, starts at z_min and works towards -ve z
845 // and object should then be printed other way up
846 for (i= [1 : 1 : case_struts_count]) {
850 mirror([0,0, th<0 ? 1 : 0])
852 -phone_height * i / (case_struts_count+1),
853 case_struts_solid_below])
854 linear_extrude(height= abs(th)
855 -(case_struts_solid_below+case_struts_solid_above))
856 rectfromto([ x_start, -0.5 * case_struts_width ],
857 [ phone_width - x_start, +0.5 * case_struts_width ]);
861 module OrdinaryRearAperture(rhs,bot, pos){
862 Flip_rhs(rhs) Flip_bot(bot)
865 translate(pos + bumper)
869 module MicroUSBEtc(){
873 linextr(-epp2i[0], 60)
874 translate([0.5 * phone_width, 0, 0])
875 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
876 [+microusb_width/2, epp0[1] + -microusb_above]);
880 module OrdinaryBottomEdgeApertures(){
882 CaseAperture(mainmic_pos, mainmic_dia, 8);
884 Flip_bot(1) Flip_rhs(1) {
885 linextr_y_xz(-epp2i[0], 60)
888 translate([ -bottomspeaker_pos[0], -bottomspeaker_pos[1] ] +
889 [ 0.5 * x * bottomspeaker_size[0] - bottomspeaker_size[1],
892 circle(r = bottomspeaker_size[1], $fn = 8);
897 module OrdinaryRearApertures(){
899 // OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
900 // rectfromto(-rearspeaker_gap,
901 // rearspeaker_size + rearspeaker_gap);
904 module NotInTestFrameRearApertures(){
905 // finger hole to remove phone
906 if (len(fingerpushhole_dias))
907 OrdinaryRearAperture(0,0, [ fingerpushhole_dias[0] + epp2i[0],
909 scale(fingerpushhole_dias)
913 module RearCameraAperture(){
917 hull() // there is some kind of bug if hull() is done in 2D here!
918 linear_extrude(height = 20)
921 translate(camera_pos_tl)
922 for (xy = [ [0,0], [0,1], [1,0] ]) {
924 camera_edge_rad * [1,1] +
925 xy * (camera_sz - camera_edge_rad * 2)
927 circle(r = camera_edge_rad);
931 module HingeLidProfile(){
933 circleat(hppT, hp_r1);
934 circleat(lpp12, lp_r12);
942 module HingeBaseProfile(){
945 circleat(hppB, hp_r1);
946 circleat(hppE, hp_r1);
947 circleat(epp2o, case_th_bottom);
948 circleat(hppB + [10,0], hp_r1);
950 polygon([epp5, epp1, epp3, bppL]);
954 module HingeLeverOuterProfile(){
956 circleat(hppT, hp_r2);
957 circleat(hppB, hp_r2);
961 module HingeLeverInnerProfile(){
963 c = s > 0 ? hppT : hppB;
965 mirror([0,0, s>0 ? 1 : 0])
966 rotate(s<0 ? -40 : 0)
975 module HingeLeverNutProfile(){
976 for (c= [hppB, hppT]) {
978 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
982 module Flip_hinge(doflip=1){
983 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
984 translate(hinge_origin)
985 rotate([doflip*180,0,0])
986 translate(-hinge_origin)
990 module HingePortion(x0,x1){
991 Flip_rhs() Flip_bot(1)
995 linear_extrude(height=x1-x0)
999 module ThumbRecessApply(ztop){
1000 width = thumbrecess_width;
1001 w = width + thumbrecess_topcurve_r*2 + 1;
1002 translate([phone_width/2, 0,0]){
1007 translate([0, 50, 0])
1009 linear_extrude(height=100){
1010 for (m=[0,1]) mirror([m,0,0]) {
1012 translate([w/2, ztop - thumbrecess_topcurve_r])
1013 circle(thumbrecess_topcurve_r);
1014 translate([w/2, -50])
1015 square(thumbrecess_topcurve_r*2, center=true);
1024 AroundEdges(epp3[1], case_th_bottom, 1)
1028 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
1030 module PropProfileAssignments(gamma){
1031 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
1033 p = phone_height + prlp10[0] - hppB[0];
1036 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
1038 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
1039 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
1041 $prp_theta = 90 - $prp_alpha;
1042 beta = 180 - $prp_alpha - gamma;
1045 //echo("abc", a,b,c);
1047 v1 = [ [ cos(psi), -sin(psi) ], // x
1048 [ sin(psi), cos(psi) ] ]; // y
1050 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1053 $prp_r11 = prop_main_th/2;
1055 $prpp1 = $prpp7 + [1,0] *
1056 // this is approximate, but will do
1057 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1060 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1061 $prpp12 = $prpp3 + v1[0] *
1062 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1063 $prp_r8 = prop_main_th;
1064 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1066 $prpp5 = [ $prpp12[0] - $prp_r5,
1067 $prpp3[1] - prop_prong_h + $prp_r5 ];
1068 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1069 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1070 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1071 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1076 module PropProfile(gamma, cut=0, rot=0){
1077 PropProfileAssignments(gamma){
1079 //#circleat($prpp3,1);
1080 //#circleat($prpp12,1);
1087 polygon([[-20,-0], [20,20], [0,0]]);
1089 rectfromto($prpp6, $prpp9);
1090 translate($prpp5) intersection(){
1092 polygon([[-10,-10], [0,0], [10,0]]);
1094 rectfromto($prpp12 + [0,-0.1], $prpp3);
1097 circleat($prpp1, $prp_r1);
1098 rectfromto($prpp12 + [0,-0.1], $prpp3);
1102 rotate([0,0, rot*-$prp_theta]){
1104 extra = cut ? prop_recess_slop : 0;
1105 rectfromto($prpp6, $prpp9);
1106 circleat($prpp11, $prp_r11 + extra);
1107 circleat($prpp10, $prp_r10 + extra);
1113 module PropAggregateProfile(){
1114 for (angle = prop_angles)
1115 PropProfile(angle, 0,0);
1118 module Prop(){ ////toplevel
1119 hw = prop_main_width/2;
1121 PropAggregateProfile();
1124 module Case(){ ////toplevel
1129 // ledge (fixed keeper)
1130 Flip_rhs(1-keeper_side) intersection(){
1132 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1133 KeeperProfile(fatter=0, slant=1);
1135 // outline of the whole case, to stop it protruding
1136 translate([0,0, -25])
1137 linear_extrude(height = 50)
1140 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1144 HingePortion(hex20, hex21) HingeBaseProfile();
1146 // buildout for prop recess
1147 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1148 linextr(case_bottom_z, epp2i[1])
1151 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1153 r = epp2o[0] - prcp2[0]);
1158 Flip_rhs(keeper_side)
1159 translate([0, -phone_cnr_rad, 0])
1161 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1163 KeeperProfile(fatter=keeper_fatter_hole);
1164 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1165 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1169 RearCameraAperture();
1171 // struts (invisible, because they're buried in the case)
1172 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1177 if (!($button_leg_only && enable_support))
1179 translate([0,0,-10])
1180 linear_extrude(height= 20)
1181 ButtonPlan($button_l, 0,1);
1182 if ($button_leg_only)
1184 translate([phone_width/2, -400, kppe[1]])
1185 mirror([1-abs($rhsflip - keeper_side),0,0])
1186 cube([400, 800, 50]);
1187 if (enable_support && !$button_suppress_over_keeper)
1189 translate([-400, -400, kppd[1]])
1191 cube([800,800,100]);
1193 translate([0,0, -bppR[0]])
1194 linear_extrude(height= 20)
1195 ButtonPlan($button_l, 1,1);
1200 // apertures along top edge
1201 if (!$suppress_forward_holes) {
1202 // CaseAperture(jack_pos, jack_dia, 8);
1204 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1205 CaseAperture(lhshole_pos, noisecancelmic_dia, 8, 1);
1208 OrdinaryBottomEdgeApertures();
1210 OrdinaryRearApertures();
1211 NotInTestFrameRearApertures();
1215 // gaps for the lid's hinge arms
1216 HingePortion(hex20 - hinge_x_arms_gap,
1217 hex21 + hinge_x_arms_gap)
1220 circle(r= hinge_r_arms_gap, $fn= 8);
1223 // screw holes in the hinge arms
1227 ThumbRecessApply(epp4[1])
1228 ThumbRecessCutProfile();
1232 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1233 rotate([0, ly_theta, 0])
1235 LanyardCutout(lanyard_channel_len);
1239 translate([prop_x_pos,0,0])
1242 linextr(-prop_recess_hw, +prop_recess_hw)
1244 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1245 circleat(prcp1 + 20*d,
1251 module LidAdhocMultiprintFrame(phase){
1252 if (led_window_style >= 3) {
1253 AdhocMultiprintFrame(phase, lpp13[1], -1);
1257 module LidAroundEdges(){
1258 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1262 module Lid(){ ////toplevel
1263 skew_centre = [0, lpp11[0], lpp11[1]];
1270 translate(skew_centre)
1271 multmatrix([[ 1, 0, 0, 0 ],
1272 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1275 translate(-skew_centre)
1277 LidEdgeFoldClearanceProfile();
1284 translate([0,0,-10])
1285 linear_extrude(height= 20)
1286 ButtonPlan($button_l, 1,0);
1289 translate([0,0,-100])
1290 linear_extrude(height= 200)
1291 ButtonCoverProfile();
1293 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1294 - lid_buttoncover_reinf))
1302 HingePortion(hex20, hex21) {
1307 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1309 // screw holes in the hinge arms
1313 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1316 linextr(-prop_recess_hw, +prop_recess_hw)
1318 for (pa = prop_angles)
1319 PropProfile(pa, 1,1);
1321 // notification led aperture
1322 if (led_window_style)
1323 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1324 translate([0,0,-10])
1325 cylinder(r=nla_r0, h=20);
1326 if (led_window_style >= 2)
1327 translate([0,0, -nla_t])
1328 cylinder(r=nla_r2, height=20);
1333 LidAdhocMultiprintFrame(1);
1336 module HingeLever(){ ////toplevel
1338 // outer body, positive
1339 HingePortion(hex22, hex22 + phone_width/2)
1340 HingeLeverOuterProfile();
1342 // space for the screws
1343 // HingePortion(hex26, hex24)
1344 // HingeLeverInnerProfile();
1346 // recesses for the nuts
1347 // HingePortion(hex23, hex26+1)
1348 // HingeLeverNutProfile();
1350 // bores for the screws
1353 // space for the charging cable and speaker and micc apertures
1359 * ( (hex24 + hinge_over_nut_plate) -
1360 (phone_width/2 - microusb_width/2)
1362 / ( (epp0[1] - microusb_above)
1364 (hppB[1] - hp_r2) ),
1366 x * (epp0[1] - microusb_above)
1373 Flip_hinge() MicroUSBEtc();
1381 module LidWindow(){ ////toplevel
1382 translate([led_pos[0], -led_pos[1], lpp13[1]])
1384 cylinder(r= nla_r1, h=nla_t);
1385 LidAdhocMultiprintFrame(0);
1388 module LidWindowPrint(){ ////toplevel
1393 module DemoLidWindowSelect(){
1394 translate([led_pos[0], led_pos[1], -100]) {
1395 translate([0, -30, 0]) cube([400, 400, 200]);
1399 module DemoLidWindow(){ ////toplevel
1402 translate([0,40,0]){
1403 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1404 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1408 module HingeLeverPrint(){ ////toplevel
1410 translate([-phone_width/2, phone_height, 0])
1414 module TestSelectLength(){
1415 translate([-30, -200, -20])
1416 cube([30 + 15, 250, 40]);
1419 module TestLength(){ ////toplevel
1426 module TestLengthRight(){ ////toplevel
1434 module TestSelectWidth(){
1435 translate([-30, -(phone_height - 25), -20])
1437 cube([200, 50, 40]);
1440 module TestWidth(){ ////toplevel
1447 module TestLidWidthPrint(){ ////toplevel
1448 rotate([0,180.0]) intersection(){
1454 module TestSelectRearAperture(){
1457 translate([20, 0,0])
1458 cube([42, 2, 1], center=true);
1462 module TestSelectCamera(){
1464 TestSelectRearAperture()
1465 RearCameraAperture();
1466 cube([0.1, 50, 0.1]);
1470 module TestSelectOrdinaryRearApertures(){
1471 TestSelectRearAperture()
1472 OrdinaryRearApertures();
1475 module TestCamera(){ ////toplevel
1482 module TestLidByCamera(){ ////toplevel
1489 module TestLidByCameraPrint(){ ////toplevel
1490 rotate([180,0,0]) TestLidByCamera();
1493 module DemoByCamera(){ ////toplevel
1494 color("blue") TestLidByCamera();
1495 color("red") TestCamera();
1498 module OneKeeper(){ ////toplevel
1499 translate([0, -phone_cnr_rad, 0])
1501 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1502 KeeperProfile(fatter=keeper_fatter);
1505 module OneKeeperPrint(){ ////toplevel
1510 module LidPrint(){ ////toplevel
1515 module TestSelectFrame(){
1516 include = [1,-1] * (epp2i[0] + 4);
1519 cube(1000, center=true);
1520 translate([0,0, -100])
1521 linear_extrude(height=200)
1522 rectfromto(include, inside_br - include);
1526 translate([ 0, -phone[1] * i/3, 0 ])
1527 cube(center=true, [1000, 4, 100]);
1531 module TestSelectLidFrame(){
1534 translate([led_pos[0], -led_pos[1], -50])
1535 cylinder(r= nla_r2+3, h=100);
1538 module TestFrameCase(){ ////toplevel
1544 TestSelectOrdinaryRearApertures();
1549 module TestSelectTopApertures(){
1550 translate([-100, -35, -100])
1551 cube([400, 100, 200]);
1552 LidAdhocMultiprintFrame(0);
1553 LidAdhocMultiprintFrame(1);
1556 module TestTopApertures(){ ////toplevel
1560 TestSelectTopApertures();
1564 module TestLidTopAperturesPrint(){ ////toplevel
1565 rotate([0,180,0]) intersection(){
1567 TestSelectLidFrame();
1568 TestSelectTopApertures();
1572 module TestLidWindowTopAperturesPrint(){ ////toplevel
1573 rotate([0,180,0]) intersection(){
1575 TestSelectTopApertures();
1579 module TestFrameLidPrint(){ ////toplevel
1580 rotate([0,180,0]) intersection(){
1582 TestSelectLidFrame();
1586 module ButtonPlanForDemo(z, deep, cut){
1588 ButtonPlan(8, deep, cut);
1591 module HingeScrews(){
1592 Flip_rhs() Flip_bot(1){
1593 for (c= [ hppT, hppB ])
1598 translate([0,0,-.2])
1599 cylinder( r= hingescrew_shaft_dia/2,
1600 h = hingescrew_shaft_len+0.2 );
1602 translate([0,0,+.1])
1603 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1608 module DemoPropAngleSelect(c){
1609 color(c) difference(){
1610 union(){ children(); }
1611 translate([ prop_x_pos, -400, -200 ])
1612 cube([ 400,800,400 ]);
1616 module DemoPropAngle(ang){
1617 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1618 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1626 DemoPropAngleSelect("red") Case();
1629 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1630 PropProfileAssignments(ang) {
1632 rotate([-$prp_theta, 0, 0])
1633 translate([0, $prpp1[0], -$prpp1[1]])
1639 translate([0,0, -hp_k*2])
1640 DemoPropAngleSelect("blue")
1644 module DemoPropAngles(){ ////toplevel
1645 for (i=[0 : len(prop_angles)-1])
1646 translate(i * [0, -100, 100])
1647 DemoPropAngle(prop_angles[i]);
1650 module DemoHingeAngle(ang1,ang2){
1651 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1652 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1663 color("blue") intersection(){
1666 translate([bppJ[0], -400, -200])
1668 cube([400, 800, 400]);
1669 translate([10, -400, -200])
1670 cube([10, 800, 400]);
1675 module DemoHingeAngles(){ ////toplevel
1676 angles = [ 0, 4, 8, 12 ];
1677 echo("angles",angles);
1678 for (i=[0 : len(angles)-1]) {
1679 translate(i * [0, 0, 30]) {
1680 DemoHingeAngle(0,angles[i]);
1681 translate([0, 200, 0])
1682 DemoHingeAngle(angles[i],0);
1687 module DemoSelectAdhocLeftRight(right=0) {
1688 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1689 mirror([1-right, 0,0])
1690 cube([400, 800, 200]);
1693 module DemoLeft(){ ////toplevel
1694 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1695 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1698 module DemoFrame(){ ////toplevel
1699 color("red") render() TestFrameCase();
1700 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1701 color("black") render() HingeScrews();
1702 %render() HingeLever();
1705 module DemoLanyardCutout(){ ////toplevel
1709 module DemoHingedFrame(){ ///toplevel
1710 color("red") render() TestFrameCase();
1711 translate([0,0, -2*hp_k])
1712 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1715 color("orange") render() HingeLever();
1716 color("black") render() HingeScrews();
1720 module DemoHinge(){ ////toplevel
1721 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1723 translate([0,0, -hp_k*3])
1728 module DemoProfiles(){ ////toplevel
1732 translate([0,0,-1]) color("black") KeeperProfile(1);
1735 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1736 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1737 translate([0, ly_q_z]){
1738 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1739 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1743 translate([0,0,-5]) color("white") translate(epp2i)
1745 rectfromto([-15, 0],
1746 [+15, -max_case_bottom_edge_thickness]);
1749 LanyardMainChannelProfile();
1750 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1751 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1758 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1760 color("blue") ButtonCoverProfile();
1762 rectfromto(bppQ, demopoint_QR);
1763 rectfromto(bppR, demopoint_QR);
1767 translate([-20,0]) {
1768 color("black") ButtonPlanForDemo(-2, 0,1);
1769 color("red" ) ButtonPlanForDemo(-4, 1,1);
1770 color("blue") ButtonPlanForDemo(-6, 1,0);
1773 translate([0, -30]) {
1776 color("blue") HingeLidProfile();
1777 color("red") HingeBaseProfile();
1778 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1782 translate([-30, -60 + 30*f]) {
1783 translate([0,0,-4]) EdgeProfile();
1784 %translate([0,0,-10]) HingeBaseProfile();
1785 translate([0,-2] * f * hp_k) {
1786 translate([0,0,-4]) LidEdgeProfile();
1787 %translate([0,0,-10]) %HingeLidProfile();
1789 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1790 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1791 translate([0,0,0]) color("red") difference(){
1792 HingeLeverOuterProfile();
1793 HingeLeverInnerProfile();
1795 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1800 translate([20,-30]) {
1803 //translate([0,0,1]) ThumbRecessCutProfile();
1804 translate([0,0,+1]) color("red")
1805 difference(){ EdgeProfile(); ThumbRecessCutProfile(); }
1808 translate([40,-30]) {
1812 PropProfile(10, 1, 0);
1817 translate([60,-30]) {
1818 PropAggregateProfile();