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;
68 foldover_lever_gap = 0.50;
70 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
71 hingescrew_shaft_len = 12;
72 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
73 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
74 hingescrew_head_th = 1.38 + 0.75;
75 hingescrew_head_dia = 3.92;
76 lever_cover_th = 0.75;
83 buttonishleg_default_l_is_fudge = 10;
85 hinge_base_slope = 1.5; // bigger is steeper
87 strut_min_at_end = 1.5;
90 hinge_x_postscrew_gap = 0.75;
91 hinge_x_arms_gap = 0.35;
92 hinge_r_arms_gap = 0.55;
94 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
98 catch_thickness = 1.0;
99 catch_side_gap = 0.75; // each side
103 catch_finger_height = 1.5;
104 catch_finger_depth = 2.5;
106 // ---------- calculated ----------
108 phone_width = (phone + bumper*2)[0];
109 phone_height = (phone + bumper*2)[1];
111 inside_br = [phone_width, -phone_height];
113 //echo(camera_pos_tl + bumper,
114 // camera_pos_br + bumper);
116 // ----- could be changed -----
117 lid_buttoncover_gap = lid_gap_x;
118 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
120 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
122 //lid_lip_overlap_width xxx bad name = ;
123 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
126 epp1 = [0, -phone_edge_thick];
127 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
128 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
129 epp3 = epp2i + [10, 0];
130 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
131 epp4 = epp5 + [-1,0] * case_th_side;
134 kppd = kppe + [1,0] * keeper_inner_width;
135 kppc = kppd + [0,1] * keeper_th_z;
136 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
137 kppf = kppe - [0,1] * keeper_inner_height;
138 kppa = [ kppb[0], kppf[1] ];
140 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
141 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
143 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
145 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
146 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
150 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
151 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
152 bppS = [ epp1[0], bppR[1] ];
153 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
154 bppP = bppQ + [0,1] * lid_buttoncover_gap;
155 bppO = [ bppN[0], bppP[1] ];
156 bppL = lpp10 + [5,0];
157 bppK = [ bppL[0], bppN[1] ];
158 bppJ = [ bppN[0], bppL[1] ];
161 hp_rn = hingescrew_nut_dia/2;
162 hp_r2_min = hp_rn + lever_cover_th;
163 hp_rs = hingescrew_shaft_dia/2;
164 hp_r1_min = hp_rs + hingemount_th;
166 hp_r1 = max(hp_r1_min, hp_r2_min);
170 hppS = epp2o + [0,-1] * case_th_bottom;
171 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
173 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
174 0.5 * (hppU + hppS)[1] ];
175 hppT = [ hppM[0], hppU[1] - hp_r1 ];
176 hppB = hppT + [0,-1] * hp_k;
178 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
179 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
180 hppE = [ hppE_x, hppE_y ];
182 // hinge elevation x coords
184 hingescrew_portion_len =
185 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
187 hex20 = max(epp2o[0],
189 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
190 hex21 = hex20 + hingescrew_portion_len;
191 hex22 = hex21 + hinge_x_gap;
192 hex23 = hex22 + hingescrew_portion_len;
193 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
194 echo(hex20, hex21, hex22, hex23, hex24);
195 echo(hingescrew_portion_len);
199 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
200 cppA = cppJ + [lid_gap_x, -lid_gap_z];
201 cppB = [ epp0[0], cppA[1] ];
202 cppP = [ epp4[0], cppJ[1] ];
204 cppS = cppJ + [0,-1] * catch_len;
205 cppD = [ cppA[0], cppS[1] + catch_slop ];
206 cppC = [ cppB[0], cppD[1] ];
207 cppT = cppS + [1,0] * catch_depth;
208 cppU = cppT + [0,-1] * catch_height;
209 cppV = [ cppS[0], cppU[1] - catch_depth ];
211 cppR = 0.5*(cppP + cppJ);
213 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
215 cppV[1] - (catch_finger_height - cp_rQ) ];
216 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
218 // ---------- modules ----------
220 module KeeperProfile(slant=0){
221 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
222 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
225 module EdgeProfile(){
228 translate(epp3) square(case_th_bottom*2, center=true);
229 circleat(epp2o, r=case_th_bottom);
230 circleat(epp1, r=case_th_side);
231 rectfromto(epp0, epp4);
233 polygon([ epp5 + [0,10],
240 module LidEdgeProfile(){
249 circleat(lpp12, r=lp_r12);
250 rectfromto( lpp12 + [-10, 0],
251 lpp12 + [+10, +10] );
255 module ButtonCoverProfile(){
257 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
265 module ButtonPlan(l, deep, cut){
267 (cut ? 0 : lid_buttoncover_gap);
270 (deep ? lid_buttoncover_overlap : 0);
272 C = [0,0]; // by definition
276 B0 = C + [0,-1] * button_cutout_depth;
277 B1 = B0 + [0,1] * epsilon;
279 r0 = 0.5 * (T[1] - B0[1]);
280 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
281 H = A + [0,-1] * delta;
287 E1 = E0 + [1,0] * epsilon;
289 I0 = [ E0[0], H[1] ];
290 I1 = [ E1[0], H[1] ];
293 for (m=[0,1]) mirror([m,0])
294 circleat(H, r0 - epsilon);
296 for (m=[0,1]) mirror([m,0]) {
306 circleat(D, r0 + epsilon);
311 module CatchCatchProfile(){
313 for (c=[ cppR, cppQ ])
317 circleat(lpp12, lp_r12);
318 circleat(lpp12 + [5,0], lp_r12);
319 rectfromto(cppP, cppP + [5,0.1]);
321 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
324 module CatchCutProfile(){
336 module Flip_rhs(yn=[0,1]) {
338 translate([phone_width/2, 0, 0])
339 mirror([$rhsflip,0,0])
340 translate([-phone_width/2, 0, 0])
345 module Flip_bot(yn=[0,1]) {
347 translate([0, -phone_height/2, 0])
348 mirror([0, $botflip, 0])
349 translate([0, phone_height/2, 0])
354 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
357 translate([0, -phone_cnr_rad, 0])
359 linear_extrude(height = phone_height - phone_cnr_rad*2)
363 Flip_rhs() Flip_bot() {
364 translate([+1,-1] * phone_cnr_rad)
369 translate([-1,0] * phone_cnr_rad)
371 rectfromto([0,-20],[10,20]);
373 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
379 translate([ phone_width - phone_cnr_rad, 0,0 ])
381 linear_extrude(height = phone_width - phone_cnr_rad*2)
385 translate([0,0, fill_zstart])
386 mirror([0,0, fill_downwards])
387 linear_extrude(height = fill_th)
388 rectfromto([+1,-1] * phone_cnr_rad,
389 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
392 module CaseAperture(pos, dia, $fn) {
394 translate([ pos[0] + bumper[0],
397 rotate([-90, theta, 0])
398 cylinder(r = dia/2 / cos(theta),
402 module SideButton(y, y_ref_sign, l){
404 // +1 measured from top of actual phone to top of button
405 // -1 measured from bottom of actual phone to bottom of button
406 // 0 y is centre of button in coordinate system
408 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
409 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
412 translate([0, eff_y, 0])
416 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
417 $button_leg_only = true;
418 SideButton(y, y_ref_sign, l) children();
422 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
423 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
424 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
425 Flip_rhs( ) LidButtonishLeg(20, -1) children();
426 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
429 module Struts(x_start, z_min, th){
430 // if th is negative, starts at z_min and works towards -ve z
431 // and object should then be printed other way up
432 for (i= [1 : 1 : case_struts_count]) {
436 mirror([0,0, th<0 ? 1 : 0])
438 -phone_height * i / (case_struts_count+1),
439 case_struts_solid_below])
440 linear_extrude(height= abs(th)
441 -(case_struts_solid_below+case_struts_solid_above))
442 rectfromto([ x_start, -0.5 * case_struts_width ],
443 [ phone_width - x_start, +0.5 * case_struts_width ]);
447 module OrdinaryRearAperture(rhs,bot, pos){
448 Flip_rhs(rhs) Flip_bot(bot)
451 translate(pos + bumper)
459 linextr(-epp2i[0], 60)
460 translate([0.5 * phone_width, 0, 0])
461 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
462 [+microusb_width/2, epp0[1] + -microusb_above]);
466 module OrdinaryRearApertures(){
468 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
469 rectfromto(-rearspeaker_gap,
470 rearspeaker_size + rearspeaker_gap);
472 // finger hole to remove phone
473 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
475 scale(fingerpushhole_dias)
479 module RearCameraAperture(){
482 linear_extrude(height = 20)
485 rectfromto(camera_pos_tl, camera_pos_br);
488 module HingeLidProfile(){
490 circleat(hppT, hp_r1);
491 circleat(lpp12, lp_r12);
499 module HingeBaseProfile(){
502 circleat(hppB, hp_r1);
503 circleat(hppE, hp_r1);
504 circleat(epp2o, case_th_bottom);
505 circleat(hppB + [10,0], hp_r1);
507 polygon([epp5, epp1, epp2i, epp3, bppL]);
511 module HingeLeverOuterProfile(){
513 circleat(hppT, hp_r2);
514 circleat(hppB, hp_r2);
518 module HingeLeverInnerProfile(){
519 for (c = [hppT, hppB]) {
524 circleat(hppB, hp_rn);
529 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
530 translate(hinge_origin)
532 translate(-hinge_origin)
536 module HingePortion(x0,x1){
537 Flip_rhs() Flip_bot(1)
541 linear_extrude(height=x1-x0)
545 module CatchPortion(width){
546 translate([phone_width/2, 0,0])
548 linextr(-width/2, width/2)
553 AroundEdges(epp3[1], case_th_bottom, 1)
557 module Case(){ ////toplevel
562 // ledge (fixed keeper)
565 linear_extrude(height = phone_height + phone_cnr_rad * 2)
568 // outline of the whole case, to stop it protruding
569 translate([0,0, -25])
570 linear_extrude(height = 50)
572 // Flip_rhs() // actually, we only care about the LH
574 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
578 HingePortion(hex20, hex21) HingeBaseProfile();
583 translate([0, -phone_cnr_rad, 0])
585 linear_extrude(height = phone_height + phone_cnr_rad * 2)
588 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
589 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
593 RearCameraAperture();
595 // struts (invisible, because they're buried in the case)
596 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
603 linear_extrude(height= 20)
604 ButtonPlan($button_l, 0,1);
605 if ($button_leg_only)
607 translate([phone_width/2, -400, kppe[1]])
608 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
610 translate([0,0, -bppR[0]])
611 linear_extrude(height= 20)
612 ButtonPlan($button_l, 1,1);
616 // apertures along top edge
617 CaseAperture(jack_pos, jack_dia, 8);
619 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
621 OrdinaryRearApertures();
625 // gaps for the lid's hinge arms
626 HingePortion(hex20 - hinge_x_arms_gap,
627 hex21 + hinge_x_arms_gap)
630 circle(r= hinge_r_arms_gap, $fn= 8);
633 // screw holes in the hinge arms
637 CatchPortion(catch_width + catch_side_gap*2)
642 module Lid(){ ////toplevel
645 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
653 linear_extrude(height= 20)
654 ButtonPlan($button_l, 1,0);
656 translate([0,0,-100])
657 linear_extrude(height= 200)
658 ButtonCoverProfile();
663 HingePortion(hex20, hex21) HingeLidProfile();
666 CatchPortion(catch_width)
669 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
671 // screw holes in the hinge arms
676 module HingeLever(){ ////toplevel
678 // outer body, positive
679 HingePortion(hex22, hex22 + phone_width/2)
680 HingeLeverOuterProfile();
682 // space for the screws
683 HingePortion(hex23, hex24)
684 HingeLeverInnerProfile();
686 // bores for the screws
689 // space for the charging cable
691 Flip_hinge() MicroUSB();
695 module HingeLeverPrint(){ ////toplevel
700 module TestSelectLength(){
701 translate([-30, -200, -20])
702 cube([30 + 15, 250, 40]);
705 module TestLength(){ ////toplevel
712 module TestLengthRight(){ ////toplevel
720 module TestSelectWidth(){
721 translate([-30, -(phone_height - 25), -20])
726 module TestWidth(){ ////toplevel
733 module TestLidWidthPrint(){ ////toplevel
734 rotate([0,180.0]) intersection(){
740 module TestSelectRearAperture(){
744 cube([42, 2, 1], center=true);
748 module TestSelectCamera(){
750 TestSelectRearAperture()
751 RearCameraAperture();
752 cube([0.1, 50, 0.1]);
756 module TestSelectOrdinaryRearApertures(){
757 TestSelectRearAperture()
758 OrdinaryRearApertures();
761 module TestCamera(){ ////toplevel
768 module TestLidByCamera(){ ////toplevel
775 module TestLidByCameraPrint(){ ////toplevel
776 rotate([180,0,0]) TestLidByCamera();
779 module DemoByCamera(){ ////toplevel
780 color("blue") TestLidByCamera();
781 color("red") TestCamera();
784 module OneKeeper(){ ////toplevel
785 translate([0, -phone_cnr_rad, 0])
787 linear_extrude(height = phone_height - phone_cnr_rad * 2)
791 module OneKeeperPrint(){ ////toplevel
796 module LidPrint(){ ////toplevel
801 module TestSelectFrame(){
802 include = [1,-1] * (epp2i[0] + 4);
805 cube(1000, center=true);
806 translate([0,0, -100])
807 linear_extrude(height=200)
808 rectfromto(include, inside_br - include);
812 module TestFrameCase(){ ////toplevel
818 TestSelectOrdinaryRearApertures();
823 module TestFrameLidPrint(){ ////toplevel
824 rotate([0,180,0]) intersection(){
830 module Keeper(){ ////toplevel
835 module ButtonPlanForDemo(z, deep, cut){
837 ButtonPlan(8, deep, cut);
840 module HingeScrews(){
841 Flip_rhs() Flip_bot(1){
842 for (c= [ hppT, hppB ])
848 cylinder( r= hingescrew_shaft_dia/2,
849 h = hingescrew_shaft_len+0.2 );
852 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
857 module DemoFrame(){ ////toplevel
858 color("red") TestFrameCase();
859 color("blue") intersection(){ Lid(); TestSelectFrame(); }
860 color("black") HingeScrews();
864 module DemoHingedFrame(){ ///toplevel
865 color("red") TestFrameCase();
866 translate([0,0, -2*hp_k])
867 color("blue") intersection(){ Lid(); TestSelectFrame(); }
870 color("orange") HingeLever();
871 color("black") HingeScrews();
875 module DemoHinge(){ ////toplevel
877 translate([0,0, -hp_k*3])
881 module DemoProfiles(){ ////toplevel
885 translate([0,0,-1]) color("black") KeeperProfile(1);
891 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
893 color("blue") ButtonCoverProfile();
895 rectfromto(bppQ, demopoint_QR);
896 rectfromto(bppR, demopoint_QR);
901 color("black") ButtonPlanForDemo(-2, 0,1);
902 color("red" ) ButtonPlanForDemo(-4, 1,1);
903 color("blue") ButtonPlanForDemo(-6, 1,0);
906 translate([0, -30]) {
909 color("blue") HingeLidProfile();
910 color("red") HingeBaseProfile();
911 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
912 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
915 translate([20,-30]) {
918 //translate([0,0,1]) CatchCutProfile();
919 color("blue") CatchCatchProfile();
920 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }