5 phone = [ 75.0, 145.0 ];
7 bumper = [ 0.250, -0.025 ];
8 // ^ One side. Overall size is increased by twice this.
9 // If no bumpers, is the gap around the phone.
13 button_cutout_depth = 9;
15 phone_edge_thick = 9.0;
16 phone_total_thick = 12.0;
17 phone_backside_slope_inner = 1.5; // larger means shallower
18 phone_backside_slope_outer = 1.0; // larger means shallower
20 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
21 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
23 jack_pos = [ 13.92, 7.96 ];
24 jack_dia = 9.1 + .5; // some jack I had lying around
26 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
27 noisecancelmic_dia = 1.75;
29 fingerpushhole_dias = [ 15, 18 ];
31 rearspeaker_pos_bl = [ 12.64, 18.72 ];
32 rearspeaker_size = [ 3.76, 7.36 ];
34 microusb_above = 3.27 - 0.25;
36 microusb_width = 16.12 + 0.25;
43 case_struts_count = 6;
44 case_struts_solid_below = 1.00;
45 case_struts_solid_above = 0.75;
46 case_struts_width = 0.10;
50 keeper_inner_width = 2.75;
51 keeper_inner_height = 2.75;
52 keeper_slant_slope = 2; // larger means steeper
54 keeper_gap_z_top = 0.25;
55 keeper_gap_z_bot = 0.75;
57 keeper_gap_x_holes = 0.75;
59 keeper_side = 0; // 0 = lhs; 1 = rhs
70 foldover_lever_gap = 0.50;
72 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
73 hingescrew_shaft_len = 12;
74 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
75 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
76 hingescrew_head_th = 1.38 + 0.75;
77 hingescrew_head_dia = 3.92;
78 lever_cover_th = 0.75;
85 buttonishleg_default_l_is_fudge = 10;
87 hinge_base_slope = 1.5; // bigger is steeper
89 strut_min_at_end = 1.5;
92 hinge_x_postscrew_gap = 0.75;
93 hinge_x_arms_gap = 0.35;
94 hinge_r_arms_gap = 0.55;
96 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
100 catch_thickness = 1.0;
101 catch_side_gap = 0.75; // each side
105 catch_finger_height = 1.5;
106 catch_finger_depth = 2.5;
108 // ---------- calculated ----------
110 phone_width = (phone + bumper*2)[0];
111 phone_height = (phone + bumper*2)[1];
113 inside_br = [phone_width, -phone_height];
115 //echo(camera_pos_tl + bumper,
116 // camera_pos_br + bumper);
118 // ----- could be changed -----
119 lid_buttoncover_gap = lid_gap_x;
120 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
122 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
124 //lid_lip_overlap_width xxx bad name = ;
125 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
128 epp1 = [0, -phone_edge_thick];
129 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
130 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
131 epp3 = epp2i + [10, 0];
132 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
133 epp4 = epp5 + [-1,0] * case_th_side;
136 kppd = kppe + [1,0] * keeper_inner_width;
137 kppc = kppd + [0,1] * keeper_th_z;
138 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
139 kppf = kppe - [0,1] * keeper_inner_height;
140 kppa = [ kppb[0], kppf[1] ];
142 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
143 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
145 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
147 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
148 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
152 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
153 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
154 bppS = [ epp1[0], bppR[1] ];
155 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
156 bppP = bppQ + [0,1] * lid_buttoncover_gap;
157 bppO = [ bppN[0], bppP[1] ];
158 bppL = lpp10 + [5,0];
159 bppK = [ bppL[0], bppN[1] ];
160 bppJ = [ bppN[0], bppL[1] ];
163 hp_rn = hingescrew_nut_dia/2;
164 hp_r2_min = hp_rn + lever_cover_th;
165 hp_rs = hingescrew_shaft_dia/2;
166 hp_r1_min = hp_rs + hingemount_th;
168 hp_r1 = max(hp_r1_min, hp_r2_min);
172 hppS = epp2o + [0,-1] * case_th_bottom;
173 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
175 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
176 0.5 * (hppU + hppS)[1] ];
177 hppT = [ hppM[0], hppU[1] - hp_r1 ];
178 hppB = hppT + [0,-1] * hp_k;
180 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
181 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
182 hppE = [ hppE_x, hppE_y ];
184 // hinge elevation x coords
186 hingescrew_portion_len =
187 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
189 hex20 = max(epp2o[0],
191 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
192 hex21 = hex20 + hingescrew_portion_len;
193 hex22 = hex21 + hinge_x_gap;
194 hex23 = hex22 + hingescrew_portion_len
195 - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
196 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
197 echo(hex20, hex21, hex22, hex23, hex24);
198 echo(hingescrew_portion_len);
202 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
203 cppA = cppJ + [lid_gap_x, -lid_gap_z];
204 cppB = [ epp0[0], cppA[1] ];
205 cppP = [ epp4[0], cppJ[1] ];
207 cppS = cppJ + [0,-1] * catch_len;
208 cppD = [ cppA[0], cppS[1] + catch_slop ];
209 cppC = [ cppB[0], cppD[1] ];
210 cppT = cppS + [1,0] * catch_depth;
211 cppU = cppT + [0,-1] * catch_height;
212 cppV = [ cppS[0], cppU[1] - catch_depth ];
214 cppR = 0.5*(cppP + cppJ);
216 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
218 cppV[1] - (catch_finger_height - cp_rQ) ];
219 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
221 // ---------- modules ----------
223 module KeeperProfile(slant=0){
224 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
225 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
228 module EdgeProfile(){
231 translate(epp3) square(case_th_bottom*2, center=true);
232 circleat(epp2o, r=case_th_bottom);
233 circleat(epp1, r=case_th_side);
234 rectfromto(epp0, epp4);
236 polygon([ epp5 + [0,10],
243 module LidEdgeProfile(){
252 circleat(lpp12, r=lp_r12);
253 rectfromto( lpp12 + [-10, 0],
254 lpp12 + [+10, +10] );
258 module ButtonCoverProfile(){
260 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
268 module ButtonPlan(l, deep, cut){
270 (cut ? 0 : lid_buttoncover_gap);
273 (deep ? lid_buttoncover_overlap : 0);
275 C = [0,0]; // by definition
279 B0 = C + [0,-1] * button_cutout_depth;
280 B1 = B0 + [0,1] * epsilon;
282 r0 = 0.5 * (T[1] - B0[1]);
283 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
284 H = A + [0,-1] * delta;
290 E1 = E0 + [1,0] * epsilon;
292 I0 = [ E0[0], H[1] ];
293 I1 = [ E1[0], H[1] ];
296 for (m=[0,1]) mirror([m,0])
297 circleat(H, r0 - epsilon);
299 for (m=[0,1]) mirror([m,0]) {
309 circleat(D, r0 + epsilon);
314 module CatchCatchProfile(){
316 for (c=[ cppR, cppQ ])
320 circleat(lpp12, lp_r12);
321 circleat(lpp12 + [5,0], lp_r12);
322 rectfromto(cppP, cppP + [5,0.1]);
324 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
327 module CatchCutProfile(){
339 module Flip_rhs(yn=[0,1]) {
341 translate([phone_width/2, 0, 0])
342 mirror([$rhsflip,0,0])
343 translate([-phone_width/2, 0, 0])
348 module Flip_bot(yn=[0,1]) {
350 translate([0, -phone_height/2, 0])
351 mirror([0, $botflip, 0])
352 translate([0, phone_height/2, 0])
357 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
360 translate([0, -phone_cnr_rad, 0])
362 linear_extrude(height = phone_height - phone_cnr_rad*2)
366 Flip_rhs() Flip_bot() {
367 translate([+1,-1] * phone_cnr_rad)
372 translate([-1,0] * phone_cnr_rad)
374 rectfromto([0,-20],[10,20]);
376 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
382 translate([ phone_width - phone_cnr_rad, 0,0 ])
384 linear_extrude(height = phone_width - phone_cnr_rad*2)
388 translate([0,0, fill_zstart])
389 mirror([0,0, fill_downwards])
390 linear_extrude(height = fill_th)
391 rectfromto([+1,-1] * phone_cnr_rad,
392 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
395 module CaseAperture(pos, dia, $fn) {
397 translate([ pos[0] + bumper[0],
400 rotate([-90, theta, 0])
401 cylinder(r = dia/2 / cos(theta),
405 module SideButton(y, y_ref_sign, l){
407 // +1 measured from top of actual phone to top of button
408 // -1 measured from bottom of actual phone to bottom of button
409 // 0 y is centre of button in coordinate system
411 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
412 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
415 translate([0, eff_y, 0])
419 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
420 $button_leg_only = true;
421 SideButton(y, y_ref_sign, l) children();
425 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
426 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
427 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
428 Flip_rhs( ) LidButtonishLeg(14, -1) children();
429 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
432 module Struts(x_start, z_min, th){
433 // if th is negative, starts at z_min and works towards -ve z
434 // and object should then be printed other way up
435 for (i= [1 : 1 : case_struts_count]) {
439 mirror([0,0, th<0 ? 1 : 0])
441 -phone_height * i / (case_struts_count+1),
442 case_struts_solid_below])
443 linear_extrude(height= abs(th)
444 -(case_struts_solid_below+case_struts_solid_above))
445 rectfromto([ x_start, -0.5 * case_struts_width ],
446 [ phone_width - x_start, +0.5 * case_struts_width ]);
450 module OrdinaryRearAperture(rhs,bot, pos){
451 Flip_rhs(rhs) Flip_bot(bot)
454 translate(pos + bumper)
462 linextr(-epp2i[0], 60)
463 translate([0.5 * phone_width, 0, 0])
464 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
465 [+microusb_width/2, epp0[1] + -microusb_above]);
469 module OrdinaryRearApertures(){
471 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
472 rectfromto(-rearspeaker_gap,
473 rearspeaker_size + rearspeaker_gap);
475 // finger hole to remove phone
476 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
478 scale(fingerpushhole_dias)
482 module RearCameraAperture(){
485 linear_extrude(height = 20)
488 rectfromto(camera_pos_tl, camera_pos_br);
491 module HingeLidProfile(){
493 circleat(hppT, hp_r1);
494 circleat(lpp12, lp_r12);
502 module HingeBaseProfile(){
505 circleat(hppB, hp_r1);
506 circleat(hppE, hp_r1);
507 circleat(epp2o, case_th_bottom);
508 circleat(hppB + [10,0], hp_r1);
510 polygon([epp5, epp1, epp2i, epp3, bppL]);
514 module HingeLeverOuterProfile(){
516 circleat(hppT, hp_r2);
517 circleat(hppB, hp_r2);
521 module HingeLeverInnerProfile(){
522 for (c = [hppT, hppB]) {
525 for (y=[0, c[1] - hppM[1]])
532 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
533 translate(hinge_origin)
535 translate(-hinge_origin)
539 module HingePortion(x0,x1){
540 Flip_rhs() Flip_bot(1)
544 linear_extrude(height=x1-x0)
548 module CatchPortion(width){
549 translate([phone_width/2, 0,0])
551 linextr(-width/2, width/2)
556 AroundEdges(epp3[1], case_th_bottom, 1)
560 module Case(){ ////toplevel
565 // ledge (fixed keeper)
566 Flip_rhs(1-keeper_side) intersection(){
568 linear_extrude(height = phone_height + phone_cnr_rad * 2)
571 // outline of the whole case, to stop it protruding
572 translate([0,0, -25])
573 linear_extrude(height = 50)
576 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
580 HingePortion(hex20, hex21) HingeBaseProfile();
584 Flip_rhs(keeper_side)
585 translate([0, -phone_cnr_rad, 0])
587 linear_extrude(height = phone_height + phone_cnr_rad * 2)
590 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
591 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
595 RearCameraAperture();
597 // struts (invisible, because they're buried in the case)
598 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
605 linear_extrude(height= 20)
606 ButtonPlan($button_l, 0,1);
607 if ($button_leg_only)
609 translate([phone_width/2, -400, kppe[1]])
610 mirror([1-abs($rhsflip - keeper_side),0,0]) cube([400, 800, 50]);
612 translate([0,0, -bppR[0]])
613 linear_extrude(height= 20)
614 ButtonPlan($button_l, 1,1);
618 // apertures along top edge
619 CaseAperture(jack_pos, jack_dia, 8);
621 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
623 OrdinaryRearApertures();
627 // gaps for the lid's hinge arms
628 HingePortion(hex20 - hinge_x_arms_gap,
629 hex21 + hinge_x_arms_gap)
632 circle(r= hinge_r_arms_gap, $fn= 8);
635 // screw holes in the hinge arms
639 CatchPortion(catch_width + catch_side_gap*2)
644 module Lid(){ ////toplevel
647 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
655 linear_extrude(height= 20)
656 ButtonPlan($button_l, 1,0);
658 translate([0,0,-100])
659 linear_extrude(height= 200)
660 ButtonCoverProfile();
665 HingePortion(hex20, hex21) HingeLidProfile();
668 CatchPortion(catch_width)
671 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
673 // screw holes in the hinge arms
678 module HingeLever(){ ////toplevel
680 // outer body, positive
681 HingePortion(hex22, hex22 + phone_width/2)
682 HingeLeverOuterProfile();
684 // space for the screws
685 HingePortion(hex23, hex24)
686 HingeLeverInnerProfile();
688 // bores for the screws
691 // space for the charging cable
693 Flip_hinge() MicroUSB();
697 module HingeLeverPrint(){ ////toplevel
702 module TestSelectLength(){
703 translate([-30, -200, -20])
704 cube([30 + 15, 250, 40]);
707 module TestLength(){ ////toplevel
714 module TestLengthRight(){ ////toplevel
722 module TestSelectWidth(){
723 translate([-30, -(phone_height - 25), -20])
728 module TestWidth(){ ////toplevel
735 module TestLidWidthPrint(){ ////toplevel
736 rotate([0,180.0]) intersection(){
742 module TestSelectRearAperture(){
746 cube([42, 2, 1], center=true);
750 module TestSelectCamera(){
752 TestSelectRearAperture()
753 RearCameraAperture();
754 cube([0.1, 50, 0.1]);
758 module TestSelectOrdinaryRearApertures(){
759 TestSelectRearAperture()
760 OrdinaryRearApertures();
763 module TestCamera(){ ////toplevel
770 module TestLidByCamera(){ ////toplevel
777 module TestLidByCameraPrint(){ ////toplevel
778 rotate([180,0,0]) TestLidByCamera();
781 module DemoByCamera(){ ////toplevel
782 color("blue") TestLidByCamera();
783 color("red") TestCamera();
786 module OneKeeper(){ ////toplevel
787 translate([0, -phone_cnr_rad, 0])
789 linear_extrude(height = phone_height - phone_cnr_rad * 2)
793 module OneKeeperPrint(){ ////toplevel
798 module LidPrint(){ ////toplevel
803 module TestSelectFrame(){
804 include = [1,-1] * (epp2i[0] + 4);
807 cube(1000, center=true);
808 translate([0,0, -100])
809 linear_extrude(height=200)
810 rectfromto(include, inside_br - include);
814 module TestFrameCase(){ ////toplevel
820 TestSelectOrdinaryRearApertures();
825 module TestFrameLidPrint(){ ////toplevel
826 rotate([0,180,0]) intersection(){
832 module ButtonPlanForDemo(z, deep, cut){
834 ButtonPlan(8, deep, cut);
837 module HingeScrews(){
838 Flip_rhs() Flip_bot(1){
839 for (c= [ hppT, hppB ])
845 cylinder( r= hingescrew_shaft_dia/2,
846 h = hingescrew_shaft_len+0.2 );
849 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
854 module DemoFrame(){ ////toplevel
855 color("red") TestFrameCase();
856 color("blue") intersection(){ Lid(); TestSelectFrame(); }
857 color("black") HingeScrews();
861 module DemoHingedFrame(){ ///toplevel
862 color("red") TestFrameCase();
863 translate([0,0, -2*hp_k])
864 color("blue") intersection(){ Lid(); TestSelectFrame(); }
867 color("orange") HingeLever();
868 color("black") HingeScrews();
872 module DemoHinge(){ ////toplevel
874 translate([0,0, -hp_k*3])
878 module DemoProfiles(){ ////toplevel
882 translate([0,0,-1]) color("black") KeeperProfile(1);
888 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
890 color("blue") ButtonCoverProfile();
892 rectfromto(bppQ, demopoint_QR);
893 rectfromto(bppR, demopoint_QR);
898 color("black") ButtonPlanForDemo(-2, 0,1);
899 color("red" ) ButtonPlanForDemo(-4, 1,1);
900 color("blue") ButtonPlanForDemo(-6, 1,0);
903 translate([0, -30]) {
906 color("blue") HingeLidProfile();
907 color("red") HingeBaseProfile();
908 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
909 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
912 translate([20,-30]) {
915 //translate([0,0,1]) CatchCutProfile();
916 color("blue") CatchCatchProfile();
917 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }