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 = [ 14, 17 ];
31 rearspeaker_pos_bl = [ 14.92, 18.72 ];
32 rearspeaker_size = [ 3.76, 7.36 ];
39 case_struts_count = 6;
40 case_struts_solid_below = 1.00;
41 case_struts_solid_above = 0.75;
42 case_struts_width = 0.10;
46 keeper_inner_width = 2.75;
47 keeper_inner_height = 2.75;
48 keeper_slant_slope = 2; // larger means steeper
50 keeper_gap_z_top = 0.25;
51 keeper_gap_z_bot = 0.75;
53 keeper_gap_x_holes = 0.75;
62 foldover_lever_gap = 0.50;
64 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
65 hingescrew_shaft_len = 12;
66 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
67 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
68 hingescrew_head_th = 1.38 + 0.75;
69 lever_cover_th = 0.75;
76 buttonishleg_default_l_is_fudge = 10;
78 strut_min_at_end = 1.5;
81 hinge_x_postscrew_gap = 0.75;
83 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
85 // ---------- calculated ----------
87 phone_width = (phone + bumper*2)[0];
88 phone_height = (phone + bumper*2)[1];
90 inside_br = [phone_width, -phone_height];
92 //echo(camera_pos_tl + bumper,
93 // camera_pos_br + bumper);
95 // ----- could be changed -----
96 lid_buttoncover_gap = lid_gap_x;
97 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
99 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
101 //lid_lip_overlap_width xxx bad name = ;
102 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
105 epp1 = [0, -phone_edge_thick];
106 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
107 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
108 epp3 = epp2i + [10, 0];
109 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
110 epp4 = epp5 + [-1,0] * case_th_side;
113 kppd = kppe + [1,0] * keeper_inner_width;
114 kppc = kppd + [0,1] * keeper_th_z;
115 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
116 kppf = kppe - [0,1] * keeper_inner_height;
117 kppa = [ kppb[0], kppf[1] ];
119 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
120 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
122 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
124 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
125 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
129 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
130 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
131 bppS = [ epp1[0], bppR[1] ];
132 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
133 bppP = bppQ + [0,1] * lid_buttoncover_gap;
134 bppO = [ bppN[0], bppP[1] ];
135 bppL = lpp10 + [5,0];
136 bppK = [ bppL[0], bppN[1] ];
137 bppJ = [ bppN[0], bppL[1] ];
140 hp_rn = hingescrew_nut_dia/2;
141 hp_r2 = hp_rn + lever_cover_th;
142 hp_rs = hingescrew_shaft_dia/2;
143 hp_r1 = hp_rs + hingemount_th;
146 hppS = epp2o + [0,-1] * case_th_bottom;
147 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
149 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
150 0.5 * (hppU + hppS)[1] ];
151 hppT = hppM + 0.5 * [0,+1] * hp_k;
152 hppB = hppM + 0.5 * [0,-1] * hp_k;
154 // hinge elevation x coords
156 hingescrew_portion_len =
157 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
159 hex20 = max(epp2o[0],
161 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
162 hex21 = hex20 + hingescrew_portion_len;
163 hex22 = hex21 - hinge_x_gap;
164 hex23 = hex22 + hingescrew_portion_len;
165 hex24 = hex23 + hinge_x_postscrew_gap;
167 // ---------- modules ----------
169 module KeeperProfile(slant=0){
170 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
171 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
174 module EdgeProfile(){
177 translate(epp3) square(case_th_bottom*2, center=true);
178 circleat(epp2o, r=case_th_bottom);
179 circleat(epp1, r=case_th_side);
180 rectfromto(epp0, epp4);
182 polygon([ epp5 + [0,10],
189 module LidEdgeProfile(){
198 circleat(lpp12, r=lp_r12);
199 rectfromto( lpp12 + [-10, 0],
200 lpp12 + [+10, +10] );
204 module ButtonCoverProfile(){
206 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
214 module ButtonPlan(l, deep, cut){
216 (cut ? 0 : lid_buttoncover_gap);
219 (deep ? lid_buttoncover_overlap : 0);
221 C = [0,0]; // by definition
225 B0 = C + [0,-1] * button_cutout_depth;
226 B1 = B0 + [0,1] * epsilon;
228 r0 = 0.5 * (T[1] - B0[1]);
229 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
230 H = A + [0,-1] * delta;
236 E1 = E0 + [1,0] * epsilon;
238 I0 = [ E0[0], H[1] ];
239 I1 = [ E1[0], H[1] ];
242 for (m=[0,1]) mirror([m,0])
243 circleat(H, r0 - epsilon);
245 for (m=[0,1]) mirror([m,0]) {
255 circleat(D, r0 + epsilon);
260 module Flip_rhs(yn=[0,1]) {
262 translate([phone_width/2, 0, 0])
263 mirror([$rhsflip,0,0])
264 translate([-phone_width/2, 0, 0])
269 module Flip_bot(yn=[0,1]) {
271 translate([0, -phone_height/2, 0])
272 mirror([0, $botflip, 0])
273 translate([0, phone_height/2, 0])
278 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
281 translate([0, -phone_cnr_rad, 0])
283 linear_extrude(height = phone_height - phone_cnr_rad*2)
287 Flip_rhs() Flip_bot() {
288 translate([+1,-1] * phone_cnr_rad)
293 translate([-1,0] * phone_cnr_rad)
295 rectfromto([0,-20],[10,20]);
297 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
303 translate([ phone_width - phone_cnr_rad, 0,0 ])
305 linear_extrude(height = phone_width - phone_cnr_rad*2)
309 translate([0,0, fill_zstart])
310 mirror([0,0, fill_downwards])
311 linear_extrude(height = fill_th)
312 rectfromto([+1,-1] * phone_cnr_rad,
313 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
316 module CaseAperture(pos, dia, $fn) {
318 translate([ pos[0] + bumper[0],
321 rotate([-90, theta, 0])
322 cylinder(r = dia/2 / cos(theta),
326 module SideButton(y, y_ref_sign, l){
328 // +1 measured from top of actual phone to top of button
329 // -1 measured from bottom of actual phone to bottom of button
330 // 0 y is centre of button in coordinate system
332 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
333 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
336 translate([0, eff_y, 0])
340 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
341 $button_leg_only = true;
342 SideButton(y, y_ref_sign, l) children();
346 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
347 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
348 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
349 Flip_rhs( ) LidButtonishLeg(20, -1) children();
350 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
353 module Struts(x_start, z_min, th){
354 // if th is negative, starts at z_min and works towards -ve z
355 // and object should then be printed other way up
356 for (i= [1 : 1 : case_struts_count]) {
360 mirror([0,0, th<0 ? 1 : 0])
362 -phone_height * i / (case_struts_count+1),
363 case_struts_solid_below])
364 linear_extrude(height= abs(th)
365 -(case_struts_solid_below+case_struts_solid_above))
366 rectfromto([ x_start, -0.5 * case_struts_width ],
367 [ phone_width - x_start, +0.5 * case_struts_width ]);
371 module OrdinaryRearAperture(rhs,bot, pos){
372 Flip_rhs(rhs) Flip_bot(bot)
375 translate(pos + bumper)
379 module OrdinaryRearApertures(){
381 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
382 rectfromto(-rearspeaker_gap,
383 rearspeaker_size + rearspeaker_gap);
385 // finger hole to remove phone
386 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
388 scale(fingerpushhole_dias)
392 module RearCameraAperture(){
395 linear_extrude(height = 20)
398 rectfromto(camera_pos_tl, camera_pos_br);
401 module HingeLidProfile(){
403 circleat(hppT, hp_r1);
404 circleat(lpp12, lp_r12);
412 module HingeBaseProfile(){
415 circleat(hppB, hp_r1);
416 circleat(epp2o, case_th_bottom);
417 circleat(hppB + [10,0], hp_r1);
419 polygon([epp5, epp1, epp2i, epp3, bppL]);
423 module HingeLeverOuterProfile(){
425 circleat(hppT, hp_r2);
426 circleat(hppB, hp_r2);
430 module HingeLeverInnerProfile(){
431 for (c = [hppT, hppB]) {
436 circleat(hppB, hp_rn);
440 module HingePortion(x0,x1){
441 Flip_rhs() Flip_bot(1)
445 linear_extrude(height=x1-x0)
450 AroundEdges(epp3[1], case_th_bottom, 1)
454 module Case(){ ////toplevel
459 // ledge (fixed keeper)
462 linear_extrude(height = phone_height + phone_cnr_rad * 2)
465 // outline of the whole case, to stop it protruding
466 translate([0,0, -25])
467 linear_extrude(height = 50)
469 // Flip_rhs() // actually, we only care about the LH
471 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
475 HingePortion(hex20, hex21) HingeBaseProfile();
480 translate([0, -phone_cnr_rad, 0])
482 linear_extrude(height = phone_height + phone_cnr_rad * 2)
485 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
486 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
490 RearCameraAperture();
492 // struts (invisible, because they're buried in the case)
493 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
500 linear_extrude(height= 20)
501 ButtonPlan($button_l, 0,1);
502 if ($button_leg_only)
504 translate([phone_width/2, -400, kppe[1]])
505 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
507 translate([0,0, -bppR[0]])
508 linear_extrude(height= 20)
509 ButtonPlan($button_l, 1,1);
513 // apertures along top edge
514 CaseAperture(jack_pos, jack_dia, 8);
516 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
518 OrdinaryRearApertures();
522 module Lid(){ ////toplevel
525 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
533 linear_extrude(height= 20)
534 ButtonPlan($button_l, 1,0);
536 translate([0,0,-100])
537 linear_extrude(height= 200)
538 ButtonCoverProfile();
542 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
546 module TestSelectLength(){
547 translate([-30, -200, -20])
548 cube([30 + 15, 250, 40]);
551 module TestLength(){ ////toplevel
558 module TestLengthRight(){ ////toplevel
566 module TestSelectWidth(){
567 translate([-30, -(phone_height - 25), -20])
572 module TestWidth(){ ////toplevel
579 module TestLidWidthPrint(){ ////toplevel
580 rotate([0,180.0]) intersection(){
586 module TestSelectRearAperture(){
590 cube([42, 2, 1], center=true);
594 module TestSelectCamera(){
596 TestSelectRearAperture()
597 RearCameraAperture();
598 cube([0.1, 50, 0.1]);
602 module TestSelectOrdinaryRearApertures(){
603 TestSelectRearAperture()
604 OrdinaryRearApertures();
607 module TestCamera(){ ////toplevel
614 module TestLidByCamera(){ ////toplevel
621 module TestLidByCameraPrint(){ ////toplevel
622 rotate([180,0,0]) TestLidByCamera();
625 module DemoByCamera(){ ////toplevel
626 color("blue") TestLidByCamera();
627 color("red") TestCamera();
630 module OneKeeper(){ ////toplevel
631 translate([0, -phone_cnr_rad, 0])
633 linear_extrude(height = phone_height - phone_cnr_rad * 2)
637 module OneKeeperPrint(){ ////toplevel
642 module LidPrint(){ ////toplevel
647 module TestSelectFrame(){
648 include = [1,-1] * (epp2i[0] + 4);
651 cube(1000, center=true);
652 translate([0,0, -100])
653 linear_extrude(height=200)
654 rectfromto(include, inside_br - include);
658 module TestFrameCase(){ ////toplevel
664 TestSelectOrdinaryRearApertures();
669 module TestFrameLidPrint(){ ////toplevel
670 rotate([0,0,180]) intersection(){
676 module Keeper(){ ////toplevel
681 module ButtonPlanForDemo(z, deep, cut){
683 ButtonPlan(8, deep, cut);
686 module DemoFrame(){ ////toplevel
687 color("red") TestFrameCase();
688 color("blue") intersection(){ Lid(); TestSelectFrame(); }
691 module DemoProfiles(){ ////toplevel
695 translate([0,0,-1]) color("black") KeeperProfile(1);
701 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
703 color("blue") ButtonCoverProfile();
705 rectfromto(bppQ, demopoint_QR);
706 rectfromto(bppR, demopoint_QR);
711 color("black") ButtonPlanForDemo(-2, 0,1);
712 color("red" ) ButtonPlanForDemo(-4, 1,1);
713 color("blue") ButtonPlanForDemo(-6, 1,0);
716 translate([0, -30]) {
719 color("blue") HingeLidProfile();
720 color("red") HingeBaseProfile();
721 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
722 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();