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 pushhole_ell_sz = 3.75;
  26 pushhole_ell_th = 1.75;
  27 pushhole_circle_dia = 2.5;
  28
  29 // for testing:
  30 battery_len = 3;
  31 //battery_wdth = 15;
  32 //battery_base_indent_fromside_inside = 6;
  33
  34 // calculated
  35
  36 bpp0 = [0,0];
  37 bpp1 = bpp0 + [ 0, mainwall_th - behind_recess ];
  38 lppA = bpp1 + [ seal_th, -recess_gap_end ];
  39 lppB = lppA + [ lid_edge_th, 0 ];
  40 bpp2 = [ lppB[0], bpp1[1] ];
  41 bpp3 = [ bpp2[0] + (bpp1 - bpp0)[1], bpp0[1] ];
  42 bpp4 = [ bpp3[0], bpp0[1] + mainwall_th ];
  43 lppC = bpp3 + [ 0, -recess_gap_end ];
  44
  45 lppF = lppC + [ handle_height, 0 ];
  46
  47 s0 = battery_wdth/2;
  48 s0i = s0 - battery_th/2;
  49 s1 = s0 + smallwall_th;
  50
  51 l1 = s1 - handle_inward;
  52 l0 = l1 - handle_len;
  53
  54 echo(
  55      bpp0,
  56      bpp1,
  57      bpp2,
  58      bpp3,
  59      bpp4,
  60      bpp5,
  61      bpp6,
  62      bpp7,
  63      bpp8
  64 );
  65
  66 echo(
  67      lppA,
  68      lppB,
  69      lppC,
  70      lppD,
  71      lppE
  72 );
  73
  74 bpp8 = bpp0 + [ -battery_len,0 ];
  75 bpp5 = [ bpp8[0] - smallwall_th, bpp4[1] ];
  76 bpp9 = [ bpp0[0], bpp0[1] - battery_th/2 - 1.0 ];
  77 bpp7 = [ bpp8[0], bpp9[1] ];
  78 bpp6 = [ bpp5[0], bpp9[1] ];
  79 lppE = [ lppA[0], bpp9[1] ];
  80 lppD = [ lppC[0], bpp9[1] ];
  81
  82 module BaseHalfPlan(indent=0){
  83   polygon([ bpp0,
  84             bpp1,
  85             bpp2,
  86             bpp3,
  87             bpp4,
  88             bpp5,
  89             bpp6,
  90             bpp7 + indent * [1,0],
  91             bpp8 + indent * [1,0]
  92             ]);
  93 }
  94
  95 module SideHalfPlan(){
  96   polygon([ bpp5,
  97             bpp6,
  98             bpp9,
  99             bpp1
 100             ]);
 101 }
 102
 103 module LidHalfPlan(){
 104   polygon([ lppA,
 105             lppE,
 106             lppD,
 107             lppC,
 108             lppB
 109             ]);
 110 }
 111
 112 module HandleHalfPlan(){
 113   translate(lppE)
 114     square(lppF - lppE);
 115 }
 116
 117 module ExtrudePlan(from,to){
 118   rotate([0,-90,0])
 119   for (mj=[0,1]) {
 120     mirror([0,0,mj]) translate([0,0,from]){
 121       linear_extrude(height= to-from){
 122         for (mi=[0,1]) {
 123           mirror([0,mi])
 124             translate([0, battery_th/2])
 125             children(0);
 126         }
 127       }
 128     }
 129   }
 130 }
 131
 132 module PushHolePlan(){ ////toplevel
 133   translate(-pushhole_ell_th * 0.5 * [1,1]) {
 134     for (r=[0,90])
 135       rotate(r)
 136         translate(-pushhole_ell_th * 0.5 * [1,1])
 137         square([ pushhole_ell_sz, pushhole_ell_th ]);
 138     circle(pushhole_circle_dia/2, $fn=20);
 139   }
 140 }
 141
 142 module PlanDemo(){ ////toplevel
 143   color("blue") BaseHalfPlan();
 144   color("red") LidHalfPlan();
 145   translate([0,0,-1]) color("lightblue") SideHalfPlan();
 146 }
 147
 148 module Base(){ ////toplevel
 149   ExtrudePlan(0,s1) BaseHalfPlan();
 150   difference(){
 151     union(){
 152       ExtrudePlan(s0i, s1) SideHalfPlan();
 153       ExtrudePlan(s0 - battery_base_indent_fromside_inside,
 154                   s0 - battery_base_indent_fromside_outside
 155                   ) BaseHalfPlan(indent = battery_base_indent);
 156     }
 157     for (m=[0,1])
 158       mirror([m,0,0])
 159         translate([s0i, 0, bpp7[0] - 0.1])
 160         cylinder(r= battery_th/2, h=100, $fs=0.5);
 161   }
 162 }
 163
 164 module BaseHalfTest(){ ////toplevel
 165   intersection(){
 166     Base();
 167     translate([-100,0,-100])
 168       cube([200,200,200]);
 169   }
 170 }
 171
 172 module Lid(){ ////toplevel
 173   ExtrudePlan(0,s1) LidHalfPlan();
 174   ExtrudePlan(l0,l1) HandleHalfPlan();
 175 }
 176
 177 module Demo(){ ////toplevel
 178   %Base();
 179   Lid();
 180 }
 181
 182 //PlanDemo();
 183 //Demo();
 184 //Base();