fairphone-battery-case.scad

   1 // -*- C -*-
   2
   3 mainwall_th = 3.0;
   4 smallwall_th = 2.0;
   5
   6 seal_th = 0.3 + 0.6 + 0.6 - 0.4 - 0.4 + 0.2; // total gap for seal etc.
   7 behind_recess = 1.5;
   8
   9 recess_gap_end = 0.4;
  10
  11 lid_edge_th = 0.5;
  12
  13 battery_len = 66.55 + 1.25 -.55;
  14 battery_th = 6.55 + 0.75 - .60;
  15 battery_wdth = 44.38 + 0.75 -.55;
  16
  17 battery_base_indent = 0.94 + 0.50;
  18 battery_base_indent_fromside_outside = 4;
  19 battery_base_indent_fromside_inside = 10;
  20
  21 handle_height = 3.5;
  22 handle_inward = 10;
  23 handle_len = 5;
  24
  25 // for testing:
  26 battery_len = 3;
  27 //battery_wdth = 15;
  28 //battery_base_indent_fromside_inside = 6;
  29
  30 // calculated
  31
  32 bpp0 = [0,0];
  33 bpp1 = bpp0 + [ 0, mainwall_th - behind_recess ];
  34 lppA = bpp1 + [ seal_th, -recess_gap_end ];
  35 lppB = lppA + [ lid_edge_th, 0 ];
  36 bpp2 = [ lppB[0], bpp1[1] ];
  37 bpp3 = [ bpp2[0] + (bpp1 - bpp0)[1], bpp0[1] ];
  38 bpp4 = [ bpp3[0], bpp0[1] + mainwall_th ];
  39 lppC = bpp3 + [ 0, -recess_gap_end ];
  40
  41 lppF = lppC + [ handle_height, 0 ];
  42
  43 s0 = battery_wdth/2;
  44 s0i = s0 - battery_th/2;
  45 s1 = s0 + smallwall_th;
  46
  47 l1 = s1 - handle_inward;
  48 l0 = l1 - handle_len;
  49
  50 echo(
  51      bpp0,
  52      bpp1,
  53      bpp2,
  54      bpp3,
  55      bpp4,
  56      bpp5,
  57      bpp6,
  58      bpp7,
  59      bpp8
  60 );
  61
  62 echo(
  63      lppA,
  64      lppB,
  65      lppC,
  66      lppD,
  67      lppE
  68 );
  69
  70 bpp8 = bpp0 + [ -battery_len,0 ];
  71 bpp5 = [ bpp8[0] - smallwall_th, bpp4[1] ];
  72 bpp9 = [ bpp0[0], bpp0[1] - battery_th/2 - 1.0 ];
  73 bpp7 = [ bpp8[0], bpp9[1] ];
  74 bpp6 = [ bpp5[0], bpp9[1] ];
  75 lppE = [ lppA[0], bpp9[1] ];
  76 lppD = [ lppC[0], bpp9[1] ];
  77
  78 module BaseHalfPlan(indent=0){
  79   polygon([ bpp0,
  80             bpp1,
  81             bpp2,
  82             bpp3,
  83             bpp4,
  84             bpp5,
  85             bpp6,
  86             bpp7 + indent * [1,0],
  87             bpp8 + indent * [1,0]
  88             ]);
  89 }
  90
  91 module SideHalfPlan(){
  92   polygon([ bpp5,
  93             bpp6,
  94             bpp9,
  95             bpp1
  96             ]);
  97 }
  98
  99 module LidHalfPlan(){
 100   polygon([ lppA,
 101             lppE,
 102             lppD,
 103             lppC,
 104             lppB
 105             ]);
 106 }
 107
 108 module HandleHalfPlan(){
 109   translate(lppE)
 110     square(lppF - lppE);
 111 }
 112
 113 module ExtrudePlan(from,to){
 114   rotate([0,-90,0])
 115   for (mj=[0,1]) {
 116     mirror([0,0,mj]) translate([0,0,from]){
 117       linear_extrude(height= to-from){
 118         for (mi=[0,1]) {
 119           mirror([0,mi])
 120             translate([0, battery_th/2])
 121             children(0);
 122         }
 123       }
 124     }
 125   }
 126 }
 127
 128 module PlanDemo(){ ////toplevel
 129   color("blue") BaseHalfPlan();
 130   color("red") LidHalfPlan();
 131   translate([0,0,-1]) color("lightblue") SideHalfPlan();
 132 }
 133
 134 module Base(){ ////toplevel
 135   ExtrudePlan(0,s1) BaseHalfPlan();
 136   difference(){
 137     union(){
 138       ExtrudePlan(s0i, s1) SideHalfPlan();
 139       ExtrudePlan(s0 - battery_base_indent_fromside_inside,
 140                   s0 - battery_base_indent_fromside_outside
 141                   ) BaseHalfPlan(indent = battery_base_indent);
 142     }
 143     for (m=[0,1])
 144       mirror([m,0,0])
 145         translate([s0i, 0, bpp7[0] - 0.1])
 146         cylinder(r= battery_th/2, h=100, $fs=0.5);
 147   }
 148 }
 149
 150 module BaseHalfTest(){ ////toplevel
 151   intersection(){
 152     Base();
 153     translate([-100,0,-100])
 154       cube([200,200,200]);
 155   }
 156 }
 157
 158 module Lid(){ ////toplevel
 159   ExtrudePlan(0,s1) LidHalfPlan();
 160   ExtrudePlan(l0,l1) HandleHalfPlan();
 161 }
 162
 163 module Demo(){ ////toplevel
 164   %Base();
 165   Lid();
 166 }
 167
 168 //PlanDemo();
 169 //Demo();
 170 //Base();