X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?a=blobdiff_plain;f=fairphone-case.scad;h=62048c83d3b7af673b9167177f03f10c64fe7436;hb=85db45c1dd57ad34e781f8d108368fa1124a2e47;hp=1785a115230b9195720209b941f22916706d2090;hpb=cd454e3e24894088eaa7ea5456875c2d0e77258a;p=reprap-play.git diff --git a/fairphone-case.scad b/fairphone-case.scad index 1785a11..04c4d61 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,7 +1,18 @@ // -*- C -*- -phone_height = 146.5 - .80; -phone_width = 76.75; +include + +phone = [ 75.0, 145.0 ]; + +prop_buildout_less = 3; + +prop_angles = [ 15, 30, 45, 60 ]; + +bumper = [ 0.250, -0.025 ]; +// ^ One side. Overall size is increased by twice this. +// If no bumpers, is the gap around the phone. + +enable_support = 1; phone_cnr_rad = 6.0; @@ -12,8 +23,24 @@ phone_total_thick = 12.0; phone_backside_slope_inner = 1.5; // larger means shallower phone_backside_slope_outer = 1.0; // larger means shallower -camera_pos_tl = [ 7.0, 13.0 ]; // measured from tl corner -camera_pos_br = [ 24.0, 39.5 ]; // tl/br as seen from back +camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner +camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back + +jack_pos = [ 13.83, 8.485 ]; +jack_dia = 10.64 + .5; // some jack I had lying around + +noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs +noisecancelmic_dia = 4.00; + +//fingerpushhole_dias = [ 15, 18 ]; +fingerpushhole_dias = []; + +rearspeaker_pos_bl = [ 12.64, 18.72 ]; +rearspeaker_size = [ 3.76, 7.36 ]; + +microusb_above = 3.27 - 0.25; +microusb_below = 0.0; +microusb_width = 16.12 + 1.25; case_th_bottom = 2.5; case_th_lid = 2.5; @@ -21,39 +48,108 @@ case_th_side = 2; case_th_lip = 1.2; case_struts_count = 6; -case_struts_solid_below = 0.75; -case_struts_solid_above = 1.00; +case_struts_solid_below = 1.00; +case_struts_solid_above = 0.75; case_struts_width = 0.10; keeper_th_z = 0.75; keeper_th_x = 0.75; keeper_inner_width = 2.75; keeper_inner_height = 2.75; +keeper_slant_slope = 2; // larger means steeper keeper_gap_z_top = 0.25; keeper_gap_z_bot = 0.75; keeper_gap_x = 0.25; keeper_gap_x_holes = 0.75; +keeper_side = 0; // 0 = lhs; 1 = rhs + case_lip = 1.25; lid_gap_x = 0.25; lid_gap_z = 0.25; lid_lip = 1.75; +catch_slop = 0.50; + +foldover_gap = 0.50; +foldover_lever_gap = 0.50; + +hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw +hingescrew_shaft_len = 12; +hingescrew_nut_thick = 1.93 + 0.20; // incl. washer +hingescrew_nut_dia = 4.72 + 0.50; // washer, actually +hingescrew_head_th = 1.38 + 0.75; +hingescrew_head_dia = 3.92; +lever_cover_th = 0.75; +hingemount_th = 2.5; + $fa = 5; $fs = 0.1; -button_l_fudge = 4.5; +button_l_fudge = 4.4; +buttonishleg_default_l_is_fudge = 10; + +hinge_base_slope = 1.5; // bigger is steeper + +strut_min_at_end = 1.5; + +hinge_x_gap = 0.125; +hinge_x_postscrew_gap = 0.75; +hinge_x_arms_gap = 0.35; +hinge_r_arms_gap = 0.55; + +rearspeaker_gap = [ 2.0, 2.0 ]; // each side + +catch_len = 7.5; +catch_width = 15; +catch_thickness = 1.0; +catch_side_gap = 0.75; // each side + +catch_depth = 0.75; +catch_height = 0.35; +catch_finger_height = 1.5; +catch_finger_depth = 2.5; + +prop_recess_under = 0.50; +prop_recess_slop = 0.200; // each side +prop_end_dia = 0.5; +prop_main_th = 3; +prop_taper_len = 6; +prop_main_width = 4; +prop_side_gap = 0.75; // each side +prop_lidrecess_behind = 0.75; +prop_caserecess_behind = 0.75; +prop_caserecess_taper = 0.45; // one side only +prop_prop_gap = 0.5; +prop_prong_heel_slope = 0.5; // ---------- calculated ---------- +phone_width = (phone + bumper*2)[0]; +phone_height = (phone + bumper*2)[1]; + +inside_br = [phone_width, -phone_height]; + +prop_prong_h = prop_main_th; + +//echo(camera_pos_tl + bumper, +// camera_pos_br + bumper); + // ----- could be changed ----- lid_buttoncover_gap = lid_gap_x; lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top; phone_backside_slope_thick = phone_total_thick - phone_edge_thick; +//prop_lidrecess_depth = case_th_lid - prop_recess_under; + +//prop_nose_len = case_th_lid - prop_recess_under; +//prop_recess_slope = tan(prop_max_angle); // bigger means steeper +//prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap; + + //lid_lip_overlap_width xxx bad name = ; //lid_lip_inner_slope = [ 5, 5 ]; // xxx @@ -74,8 +170,13 @@ kppa = [ kppb[0], kppf[1] ]; lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ]; lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ]; -lpp12 = [ epp4[0] + lid_lip, lpp11[1] ]; -lpp13 = [ lpp12[0], lpp12[1] + lid_lip ]; + +lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]); + +lpp12 = [ epp4[0] + lp_r12, lpp11[1] ]; +lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ]; + +case_bottom_z = epp2o[1] - case_th_bottom; // button profile bppM = epp4 + [0,5]; @@ -88,16 +189,107 @@ bppO = [ bppN[0], bppP[1] ]; bppL = lpp10 + [5,0]; bppK = [ bppL[0], bppN[1] ]; bppJ = [ bppN[0], bppL[1] ]; +bppU = [ bppJ[0], lpp12[1] ]; +bppV = lpp11; +bppW = lpp10; -module rectfromto(a,b) { - ab = b - a; - translate([min(a[0], b[0]), min(a[1], b[1])]) - square([abs(ab[0]), abs(ab[1])]); -} -module circleat(c,r) { translate(c) circle(r); } +// hinge plan +hp_rn = hingescrew_nut_dia/2; +hp_r2_min = hp_rn + lever_cover_th; +hp_rs = hingescrew_shaft_dia/2; +hp_r1_min = hp_rs + hingemount_th; + +hp_r1 = max(hp_r1_min, hp_r2_min); +hp_r2 = hp_r1; + +hppU = lpp13; +hppS = epp2o + [0,-1] * case_th_bottom; +hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap); -module KeeperProfile(){ - polygon([kppe, kppd, kppc, kppb, kppa, kppf]); +hppM = [ epp4[0] - foldover_lever_gap - hp_r2, + 0.5 * (hppU + hppS)[1] ]; +hppT = [ hppM[0], hppU[1] - hp_r1 ]; +hppB = hppT + [0,-1] * hp_k; + +hppE_y = epp2o[1] - case_th_bottom + hp_r1; +hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope; +hppE = [ hppE_x, hppE_y ]; + +// hinge elevation x coords + +hingescrew_portion_len = + 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap); + +hex20 = max(epp2o[0], + phone_cnr_rad, + kppd[0] + hingescrew_head_th + keeper_gap_x_holes); +hex21 = hex20 + hingescrew_portion_len; +hex22 = hex21 + hinge_x_gap; +hex23 = hex22 + hingescrew_portion_len + - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly +hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap; +//echo(hex20, hex21, hex22, hex23, hex24); +//echo(hingescrew_portion_len); + +// catch + +cppJ = [ epp4[0] + catch_thickness, lpp10[1] ]; +cppA = cppJ + [lid_gap_x, -lid_gap_z]; +cppB = [ epp0[0], cppA[1] ]; +cppP = [ epp4[0], cppJ[1] ]; + +cppS = cppJ + [0,-1] * catch_len; +cppD = [ cppA[0], cppS[1] + catch_slop ]; +cppC = [ cppB[0], cppD[1] ]; +cppT = cppS + [1,0] * catch_depth; +cppU = cppT + [0,-1] * catch_height; +cppV = [ cppS[0], cppU[1] - catch_depth ]; + +cppR = 0.5*(cppP + cppJ); + +cp_rQ = 0.5 * (cppJ[0] - cppP[0]); +cppQ = [ cppR[0], + cppV[1] - (catch_finger_height - cp_rQ) ]; +cppF = [ cppV[0] + catch_finger_depth, cppC[1] ]; + +// prop recess in case + +prop_x_pos = phone_width/2; + +prop_recess_hw = 0.5 * prop_main_width + prop_side_gap; + +prc_r1 = prop_end_dia/2; +prc_r3 = prc_r1 + prop_recess_slop; + +prcp2 = [ epp4[0] + prop_buildout_less, + case_bottom_z ]; + +prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0]; + +prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind, + epp2i[1] - prc_r3 - prop_recess_under]; + +// prop recess in lid + +prl_r10 = prop_end_dia/2; +prl_r10o = prl_r10 + prop_recess_slop; + +prlp10 = lpp10 + [1,1] * prl_r10o + + [1,0] * prop_lidrecess_behind + + [0,1] * prop_recess_under; + +// prop + +$prpp10 = [0,0]; +$prpp11 = [0, prop_taper_len]; + +$prp_r10 = prl_r10; + +// ---------- modules ---------- + +module KeeperProfile(slant=0){ + use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope; + polygon([use_e, kppd, kppc, kppb, kppa, kppf]); } module EdgeProfile(){ @@ -124,7 +316,7 @@ module LidEdgeProfile(){ lpp10 + [10, 0] ]); intersection(){ - circleat(lpp12, r=lid_lip); + circleat(lpp12, r=lp_r12); rectfromto( lpp12 + [-10, 0], lpp12 + [+10, +10] ); } @@ -132,7 +324,9 @@ module LidEdgeProfile(){ module ButtonCoverProfile(){ intersection(){ - polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]); + polygon(concat([ bppM, bppP, bppO, bppJ ], + (enable_support ? [ bppU, bppV, bppW ] : []), + [ bppL, bppK ])); hull(){ EdgeProfile(); LidEdgeProfile(); @@ -141,60 +335,89 @@ module ButtonCoverProfile(){ } module ButtonPlan(l, deep, cut){ - bigger = - (deep ? lid_buttoncover_overlap : 0) + - (cut ? 0 : -lid_buttoncover_gap); - - d_D1_y = + epsilon = (cut ? 0 : lid_buttoncover_gap); + delta = + (deep ? lid_buttoncover_overlap : 0); + C = [0,0]; // by definition T = [ 0, epp4[1] ]; G = T + [0,10]; + B0 = C + [0,-1] * button_cutout_depth; + B1 = B0 + [0,1] * epsilon; + r0 = 0.5 * (T[1] - B0[1]); A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ]; - r1 = r0 + bigger; - // | D1 - A | = r1 * 2 - // D1_y = T_y - r1 + d_D1_y - // => 4 * r1^2 = (r1-r0 + d_D1_y)^2 + (D1_x - A_x)^2 - // => D1_x = A_x + v/~ [ 4 * r1^2 - (r1-r0 + d_D1_y)^2 ] - D1 = [ A[0] - sqrt( 4*r1*r1 - pow(bigger + d_D1_y, 2) ), - T[1] - r1 + d_D1_y ]; - E1 = 0.5 * (D1 + A); - F1 = D1 + [0,10]; + H = A + [0,-1] * delta; + + D = A + [-2,0] * r0; + F = D + [0,10]; + + E0 = 0.5 * (D + A); + E1 = E0 + [1,0] * epsilon; + + I0 = [ E0[0], H[1] ]; + I1 = [ E1[0], H[1] ]; hull(){ for (m=[0,1]) mirror([m,0]) - circleat(A, r1); + circleat(H, r0 - epsilon); } for (m=[0,1]) mirror([m,0]) { difference(){ polygon([ E1, - A, - B0, + I1, + H, + B1, G, - F1, - D1 + F, + D ]); - circleat(D1, r1); + circleat(D, r0 + epsilon); } } } -module CaseBase_rhsflip(yn=[0,1]) { - for (rhs=yn) { +module CatchCatchProfile(){ + hull(){ + for (c=[ cppR, cppQ ]) + circleat(c, cp_rQ); + } + hull(){ + circleat(lpp12, lp_r12); + circleat(lpp12 + [5,0], lp_r12); + rectfromto(cppP, cppP + [5,0.1]); + } + polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]); +} + +module CatchCutProfile(){ + polygon([ cppB, + cppA, + cppD, + cppF, + cppF + [0,-10], + cppF + [-10,-10], + lpp12 + [-10,0], + lpp12 + [10,0] + ]); +} + +module Flip_rhs(yn=[0,1]) { + for ($rhsflip=yn) { translate([phone_width/2, 0, 0]) - mirror([rhs,0,0]) + mirror([$rhsflip,0,0]) translate([-phone_width/2, 0, 0]) children(); } } -module CaseBase_botflip() { - for (bot=[0,1]) { +module Flip_bot(yn=[0,1]) { + for ($botflip=yn) { translate([0, -phone_height/2, 0]) - mirror([0, bot, 0]) + mirror([0, $botflip, 0]) translate([0, phone_height/2, 0]) children(); } @@ -202,14 +425,14 @@ module CaseBase_botflip() { module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ // sides - CaseBase_rhsflip(){ + Flip_rhs(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) children(0); } // corners - CaseBase_rhsflip() CaseBase_botflip() { + Flip_rhs() Flip_bot() { translate([+1,-1] * phone_cnr_rad) intersection(){ rotate_extrude() @@ -224,7 +447,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ } } // top and bottom - CaseBase_botflip(){ + Flip_bot(){ translate([ phone_width - phone_cnr_rad, 0,0 ]) rotate([90,0,-90]) linear_extrude(height = phone_width - phone_cnr_rad*2) @@ -238,34 +461,306 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad); } +module CaseAperture(pos, dia, $fn) { + theta = 180/$fn; + translate([ pos[0] + bumper[0], + -epp2i[0], + -pos[1] ]) + rotate([-90, theta, 0]) + cylinder(r = dia/2 / cos(theta), + h = 60); +} + +module SideButton(y, y_ref_sign, l){ + // y_ref_sign: + // +1 measured from top of actual phone to top of button + // -1 measured from bottom of actual phone to bottom of button + // 0 y is centre of button in coordinate system + $button_l= l; + eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 : + y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 : + y; + //echo(eff_y); + translate([0, eff_y, 0]) + children(); +} + +module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { + $button_leg_only = true; + SideButton(y, y_ref_sign, l) children(); +} + +module Buttons(){ + Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power + Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera + Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume + Flip_rhs( ) LidButtonishLeg(14, -1) children(); +// Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); +} + +module Struts(x_start, z_min, th){ + // if th is negative, starts at z_min and works towards -ve z + // and object should then be printed other way up + for (i= [1 : 1 : case_struts_count]) { + translate([0, + 0, + z_min]) + mirror([0,0, th<0 ? 1 : 0]) + translate([0, + -phone_height * i / (case_struts_count+1), + case_struts_solid_below]) + linear_extrude(height= abs(th) + -(case_struts_solid_below+case_struts_solid_above)) + rectfromto([ x_start, -0.5 * case_struts_width ], + [ phone_width - x_start, +0.5 * case_struts_width ]); + } +} + +module OrdinaryRearAperture(rhs,bot, pos){ + Flip_rhs(rhs) Flip_bot(bot) + linextr(-20, 20) + mirror([0,1]) + translate(pos + bumper) + children(); +} + +module MicroUSB(){ + Flip_bot(1){ + rotate([90,0,0]) + mirror([0,0,1]) + linextr(-epp2i[0], 60) + translate([0.5 * phone_width, 0, 0]) + rectfromto([-microusb_width/2, epp2i[1] + microusb_below], + [+microusb_width/2, epp0[1] + -microusb_above]); + } +} + +module OrdinaryRearApertures(){ + // rear speaker + OrdinaryRearAperture(1,1, rearspeaker_pos_bl) + rectfromto(-rearspeaker_gap, + rearspeaker_size + rearspeaker_gap); + + // finger hole to remove phone + if (len(fingerpushhole_dias)) + OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0], + phone[1]/2 ]) + scale(fingerpushhole_dias) + circle(r= 0.5 ); +} + +module RearCameraAperture(){ + Flip_rhs(1) + mirror([0, 0, 1]) + linear_extrude(height = 20) + mirror([0, 1, 0]) + translate(bumper) + rectfromto(camera_pos_tl, camera_pos_br); +} + +module HingeLidProfile(){ + hull(){ + circleat(hppT, hp_r1); + circleat(lpp12, lp_r12); + polygon([lpp10, + lpp13 + [2,0], + lpp12, + hppT]); + } +} + +module HingeBaseProfile(){ + difference(){ + hull(){ + circleat(hppB, hp_r1); + circleat(hppE, hp_r1); + circleat(epp2o, case_th_bottom); + circleat(hppB + [10,0], hp_r1); + } + polygon([epp5, epp1, epp2i, epp3, bppL]); + } +} + +module HingeLeverOuterProfile(){ + hull(){ + circleat(hppT, hp_r2); + circleat(hppB, hp_r2); + } +} + +module HingeLeverInnerProfile(){ + for (s = [-1,+1]) { + c = s > 0 ? hppT : hppB; + translate(c) + mirror([0,0,s>0]) + hull() + for (x=[-20,20]) + for (y=[0, s * 10]) + translate([x,y]) + circle(hp_rn); + } +} + +module Flip_hinge(){ + hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]]; + translate(hinge_origin) + rotate([180,0,0]) + translate(-hinge_origin) + children(); +} + +module HingePortion(x0,x1){ + Flip_rhs() Flip_bot(1) + translate([x0,0,0]) + mirror([1,0,0]) + rotate([90,0,-90]) + linear_extrude(height=x1-x0) + children(0); +} + +module CatchPortion(width){ + translate([phone_width/2, 0,0]) + rotate([90,0,-90]) + linextr(-width/2, width/2) + children(0); +} + module CaseBase(){ AroundEdges(epp3[1], case_th_bottom, 1) EdgeProfile(); } +function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0]; + +module PropProfileAssignments(gamma){ + // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS) + x = prop_x(gamma); + p = phone_height + prlp10[0] - hppB[0]; + b = p + x; + + q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition + a = q + x; + c = sqrt(a*a + b*b - 2*a*b*cos(gamma)); + $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) ); + + $prp_theta = 90 - $prp_alpha; + beta = 180 - $prp_alpha - gamma; + psi = 90 - beta; + + //echo("abc", a,b,c); + + v1 = [ [ cos(psi), -sin(psi) ], // x + [ sin(psi), cos(psi) ] ]; // y + + $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ]; + + $prp_r1 = prc_r1; + $prp_r11 = prop_main_th/2; + + $prpp1 = $prpp7 + [1,0] * + // this is approximate, but will do + (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]); + $prpp3 = $prpp1 + + v1[0] * -$prp_r1 + + v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap); + $prpp12 = $prpp3 + v1[0] * + (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1])); + $prp_r8 = prop_main_th; + $prpp4 = [ prop_main_th/2, $prpp3[1] ]; + $prp_r5 = $prp_r8; + $prpp5 = [ $prpp12[0] - $prp_r5, + $prpp3[1] - prop_prong_h + $prp_r5 ]; + $prpp6 = $prpp4 + [0,-1] * (prop_prong_h + + prop_prong_heel_slope * ($prpp5[0] - $prpp4[0])); + $prpp8 = $prpp4 + [0,-1] * $prp_r8; + $prpp9 = $prpp8 + [-1,0] * $prp_r8; + + children(); +} + +module PropProfile(gamma, cut=0, rot=0){ ////toplevel + PropProfileAssignments(gamma){ + + //#circleat($prpp3,1); + //#circleat($prpp12,1); + + if (!cut) { + hull(){ + translate($prpp8) + intersection(){ + circle($prp_r8); + polygon([[-20,-0], [20,20], [0,0]]); + } + rectfromto($prpp6, $prpp9); + translate($prpp5) intersection(){ + circle($prp_r5); + polygon([[-10,-10], [0,0], [10,0]]); + } + rectfromto($prpp12 + [0,-0.1], $prpp3); + } + hull(){ + circleat($prpp1, $prp_r1); + rectfromto($prpp12 + [0,-0.1], $prpp3); + } + } + // main shaft + rotate([0,0, rot*-$prp_theta]){ + hull(){ + extra = cut ? prop_recess_slop : 0; + rectfromto($prpp6, $prpp9); + circleat($prpp11, $prp_r11 + extra); + circleat($prpp10, $prp_r10 + extra); + } + } + } +} + +module PropAggregateProfile(){ + for (angle = prop_angles) + PropProfile(angle, 0,0); +} + +module Prop(){ ////toplevel + hw = prop_main_width/2; + linextr(-hw, +hw) + PropAggregateProfile(); +} + module Case(){ ////toplevel difference(){ union(){ CaseBase(); // ledge (fixed keeper) - intersection(){ + Flip_rhs(1-keeper_side) intersection(){ rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) - KeeperProfile(); + KeeperProfile(1); // outline of the whole case, to stop it protruding translate([0,0, -25]) linear_extrude(height = 50) hull() - // CaseBase_rhsflip() // actually, we only care about the LH - CaseBase_botflip() + Flip_bot() circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); } + + // hinge + HingePortion(hex20, hex21) HingeBaseProfile(); + + // buildout for prop recess + if (prop_caserecess_buildout_r > 0) Flip_rhs(1) + linextr(case_bottom_z, epp2i[1]) + hull() { + for (dxs = [-1,+1]) + circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r, + -epp2o[0] ], + r = epp2o[0] - prcp2[0]); + } } // slot for keeper - CaseBase_rhsflip(1) + Flip_rhs(keeper_side) translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) @@ -276,69 +771,226 @@ module Case(){ ////toplevel } // front camera - CaseBase_rhsflip([1]) - mirror([0, 0, 1]) - linear_extrude(height = 20) - mirror([0, 1, 0]) - rectfromto(camera_pos_tl, camera_pos_br); + RearCameraAperture(); // struts (invisible, because they're buried in the case) - for (i= [1 : 1 : case_struts_count]) { - translate([0, - -phone_height * i / (case_struts_count+1), - epp2i[1] - case_th_bottom + case_struts_solid_below]) - linear_extrude(height= case_th_bottom - -(case_struts_solid_below+case_struts_solid_above)) - rectfromto([ epp2i[0], -0.5 * case_struts_width ], - [ phone_width - epp2i[0], +0.5 * case_struts_width ]); + Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom); + + Buttons(){ + mirror([1,0,0]) + rotate([90,0,90]) { + if (!($button_leg_only && enable_support)) + intersection(){ + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($button_l, 0,1); + if ($button_leg_only) + rotate([-90,90,0]) + translate([phone_width/2, -400, kppe[1]]) + mirror([1-abs($rhsflip - keeper_side),0,0]) + cube([400, 800, 50]); + if (enable_support) + rotate([-90,90,0]) + translate([-400, -400, kppd[1]]) + mirror([0,0,1]) + cube([800,800,100]); + } + translate([0,0, -bppR[0]]) + linear_extrude(height= 20) + ButtonPlan($button_l, 1,1); + } + } + + // apertures along top edge + CaseAperture(jack_pos, jack_dia, 8); + Flip_rhs(1) + CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8); + + OrdinaryRearApertures(); + + MicroUSB(); + + // gaps for the lid's hinge arms + HingePortion(hex20 - hinge_x_arms_gap, + hex21 + hinge_x_arms_gap) + minkowski(){ + HingeLidProfile(); + circle(r= hinge_r_arms_gap, $fn= 8); + } + + // screw holes in the hinge arms + HingeScrews(); + + // catch striker + CatchPortion(catch_width + catch_side_gap*2) + CatchCutProfile(); + + // prop recess + Flip_rhs(1) + translate([prop_x_pos,0,0]) + mirror([0,1,0]) + rotate([90,0,90]) + linextr(-prop_recess_hw, +prop_recess_hw) + hull(){ + for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ]) + circleat(prcp1 + 20*d, + prc_r3); + } } } module Lid(){ ////toplevel - AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0) - LidEdgeProfile(); + difference(){ + union(){ + AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0) + LidEdgeProfile(); + + // button covers + Buttons(){ + intersection(){ + rotate([90,0,90]) + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($button_l, 1,0); + rotate([90,0,0]) + translate([0,0,-100]) + linear_extrude(height= 200) + ButtonCoverProfile(); + } + } + + // hinge arms + HingePortion(hex20, hex21) HingeLidProfile(); + + // catch + CatchPortion(catch_width) + CatchCatchProfile(); + } + Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid); + + // screw holes in the hinge arms + HingeScrews(); + + // prop recess + translate([prop_x_pos, -prlp10[0], prlp10[1]]) + mirror([0,1,0]) + rotate([90,0,90]) + linextr(-prop_recess_hw, +prop_recess_hw) + hull() + for (pa = prop_angles) + PropProfile(pa, 1,1); + } +} + +module HingeLever(){ ////toplevel + difference() { + // outer body, positive + HingePortion(hex22, hex22 + phone_width/2) + HingeLeverOuterProfile(); + + // space for the screws + HingePortion(hex23, hex24) + HingeLeverInnerProfile(); + + // bores for the screws + HingeScrews(); + + // space for the charging cable + MicroUSB(); + Flip_hinge() MicroUSB(); + } +} + +module HingeLeverPrint(){ ////toplevel + rotate([90,0,0]) + HingeLever(); +} + +module TestSelectLength(){ + translate([-30, -200, -20]) + cube([30 + 15, 250, 40]); } module TestLength(){ ////toplevel intersection(){ Case(); - translate([-30, -200, -20]) - cube([30 + 15, 250, 40]); + TestSelectLength(); } } +module TestLengthRight(){ ////toplevel + intersection(){ + Case(); + Flip_rhs(1) + TestSelectLength(); + } +} + +module TestSelectWidth(){ + translate([-30, -(phone_height - 25), -20]) + mirror([0, 1, 0]) + cube([200, 50, 40]); +} + module TestWidth(){ ////toplevel intersection(){ Case(); - translate([-30, -(phone_height - 25), -20]) - mirror([0, 1, 0]) - cube([200, 50, 40]); + TestSelectWidth(); } } module TestLidWidthPrint(){ ////toplevel - rotate([0,180.0]) - intersection(){ - Lid(); - translate([-30, -(phone_height - 25), -20]) - mirror([0, 1, 0]) - cube([200, 50, 40]); - } + rotate([0,180.0]) intersection(){ + Lid(); + TestSelectWidth(); + } +} + +module TestSelectRearAperture(){ + minkowski(){ + union() children(); + translate([20, 0,0]) + cube([42, 2, 1], center=true); + } +} + +module TestSelectCamera(){ + minkowski(){ + TestSelectRearAperture() + RearCameraAperture(); + cube([0.1, 50, 0.1]); + } +} + +module TestSelectOrdinaryRearApertures(){ + TestSelectRearAperture() + OrdinaryRearApertures(); } module TestCamera(){ ////toplevel intersection(){ Case(); - CaseBase_rhsflip(1) - translate([0,0,-25]) - linear_extrude(height = 50) - mirror([0, 1, 0]) - rectfromto([-20, -20], - camera_pos_br + [ 5, 5 ]); + TestSelectCamera(); + } +} + +module TestLidByCamera(){ ////toplevel + intersection(){ + Lid(); + TestSelectCamera(); } } +module TestLidByCameraPrint(){ ////toplevel + rotate([180,0,0]) TestLidByCamera(); +} + +module DemoByCamera(){ ////toplevel + color("blue") TestLidByCamera(); + color("red") TestCamera(); +} + module OneKeeper(){ ////toplevel translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) @@ -351,21 +1003,146 @@ module OneKeeperPrint(){ ////toplevel OneKeeper(); } -module Keeper(){ ////toplevel - CaseBase_rhsflip() - OneKeeper(); +module LidPrint(){ ////toplevel + rotate([0,180,0]) + Lid(); +} + +module TestSelectFrame(){ + include = [1,-1] * (epp2i[0] + 4); + + difference(){ + cube(1000, center=true); + translate([0,0, -100]) + linear_extrude(height=200) + rectfromto(include, inside_br - include); + } +} + +module TestSelectLidFrame(){ + TestSelectFrame(); } -module ButtonPlanForDemo(colour, z, deep, cut){ - color(colour) - translate([0,0,z]) +module TestFrameCase(){ ////toplevel + intersection(){ + Case(); + union(){ + TestSelectFrame(); + TestSelectCamera(); + TestSelectOrdinaryRearApertures(); + } + } +} + +module TestTopApertures(){ ////toplevel + intersection(){ + Case(); + TestSelectFrame(); + translate([-100, -35, -100]) + cube([400, 100, 200]); + } +} + +module TestFrameLidPrint(){ ////toplevel + rotate([0,180,0]) intersection(){ + Lid(); + TestSelectLidFrame(); + } +} + +module ButtonPlanForDemo(z, deep, cut){ + translate([0,0,z]) ButtonPlan(8, deep, cut); } +module HingeScrews(){ + Flip_rhs() Flip_bot(1){ + for (c= [ hppT, hppB ]) + translate([ hex20, + -c[0], + c[1] ]){ + rotate([0,90,0]) + translate([0,0,-.2]) + cylinder( r= hingescrew_shaft_dia/2, + h = hingescrew_shaft_len+0.2 ); + rotate([0,-90,0]) + translate([0,0,+.1]) + cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th ); + } + } +} + +module DemoPropAngleSelect(c){ + color(c) difference(){ + union(){ children(); } + translate([ prop_x_pos, -400, -200 ]) + cube([ 400,800,400 ]); + } +} + +module DemoPropAngle(ang){ + hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2]; + hC = [0, -(phone_height - hppB[0]), hppB[1]]; + + translate(hL) + rotate([ang/2,0,0]) + translate(-hL) + translate(hC) + rotate([ang/2,0,0]) + translate(-hC) { + DemoPropAngleSelect("red") Case(); + + color("orange") + translate([prop_x_pos, -prcp1[0], prcp1[1]]) + PropProfileAssignments(ang) { + echo($prpp1); + rotate([-$prp_theta, 0, 0]) + translate([0, $prpp1[0], -$prpp1[1]]) + rotate([90,0,-90]) + Prop(); + } + } + + translate([0,0, -hp_k*2]) + DemoPropAngleSelect("blue") + Lid(); +} + +module DemoPropAngles(){ ////toplevel + for (i=[0 : len(prop_angles)-1]) + translate(i * [0, -100, 100]) + DemoPropAngle(prop_angles[i]); +} + +module DemoFrame(){ ////toplevel + color("red") TestFrameCase(); + color("blue") intersection(){ Lid(); TestSelectLidFrame(); } + color("black") HingeScrews(); + %HingeLever(); +} + +module DemoHingedFrame(){ ///toplevel + color("red") TestFrameCase(); + translate([0,0, -2*hp_k]) + color("blue") intersection(){ Lid(); TestSelectLidFrame(); } + + Flip_hinge(){ + color("orange") HingeLever(); + color("black") HingeScrews(); + } +} + +module DemoHinge(){ ////toplevel + DemoFrame(); + translate([0,0, -hp_k*3]) + DemoHingedFrame(); +} + module DemoProfiles(){ ////toplevel LidEdgeProfile(); %EdgeProfile(); KeeperProfile(); + translate([0,0,-1]) color("black") KeeperProfile(1); translate([20,0]) { LidEdgeProfile(); @@ -381,9 +1158,39 @@ module DemoProfiles(){ ////toplevel } translate([-20,0]) { - ButtonPlanForDemo("grey", -1, 0,1); - ButtonPlanForDemo("blue", -2, 1,0); - ButtonPlanForDemo("red", -3, 1,1); + color("black") ButtonPlanForDemo(-2, 0,1); + color("red" ) ButtonPlanForDemo(-4, 1,1); + color("blue") ButtonPlanForDemo(-6, 1,0); + } + + translate([0, -30]) { + %LidEdgeProfile(); + %EdgeProfile(); + color("blue") HingeLidProfile(); + color("red") HingeBaseProfile(); + color("black") translate([0,0,-2]) HingeLeverOuterProfile(); + color("orange") translate([0,0,-1]) HingeLeverInnerProfile(); + } + + translate([20,-30]) { + %EdgeProfile(); + %LidEdgeProfile(); + //translate([0,0,1]) CatchCutProfile(); + color("blue") CatchCatchProfile(); + color("red") difference(){ EdgeProfile(); CatchCutProfile(); } + } + + translate([40,-30]) { + difference(){ + LidEdgeProfile(); + translate(prlp10) + PropProfile(10, 1, 0); + } + translate(prlp10) + PropProfile(15, 0); + } + translate([60,-30]) { + PropAggregateProfile(); } } @@ -395,3 +1202,4 @@ module DemoProfiles(){ ////toplevel //LidEdgeProfile(); //KeeperProfile(); //DemoProfiles(); +//PropRecess();