fairphone-case.scad

   1 // -*- C -*-
   2
   3 phone_height = 146.5 - .80;
   4 phone_width = 76.75;
   5
   6 phone_cnr_rad = 6.0;
   7
   8 button_cutout_depth = 9;
   9
  10 phone_edge_thick = 9.0;
  11 phone_total_thick = 12.0;
  12 phone_backside_slope_inner = 1.5; // larger means shallower
  13 phone_backside_slope_outer = 1.0; // larger means shallower
  14
  15 camera_pos_tl = [  7.0, 13.0 ]; // measured from tl corner
  16 camera_pos_br = [ 24.0, 39.5 ]; // tl/br as seen from back
  17
  18 case_th_bottom = 2.5;
  19 case_th_lid = 2.5;
  20 case_th_side = 2;
  21 case_th_lip = 1.2;
  22
  23 case_struts_count = 6;
  24 case_struts_solid_below = 0.75;
  25 case_struts_solid_above = 1.00;
  26 case_struts_width = 0.10;
  27
  28 keeper_th_z = 0.75;
  29 keeper_th_x = 0.75;
  30 keeper_inner_width = 1.75;
  31 keeper_inner_height = 1.75;
  32
  33 keeper_gap_z_top = 0.25;
  34 keeper_gap_z_bot = 0.75;
  35 keeper_gap_x     = 0.25;
  36 keeper_gap_x_holes = 0.75;
  37
  38 case_lip = 1.25;
  39
  40 lid_gap_x = 0.25;
  41 lid_gap_z = 0.25;
  42 lid_lip = 1.75;
  43
  44 $fa = 5;
  45 $fs = 0.1;
  46
  47 // calculated
  48
  49 // could be changed
  50 lid_buttoncover_gap = lid_gap_x;
  51 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
  52
  53 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
  54
  55 //lid_lip_overlap_width xxx bad name = ;
  56 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
  57
  58 epp0 = [0,0];
  59 epp1 = [0, -phone_edge_thick];
  60 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
  61 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
  62 epp3 = epp2i + [10, 0];
  63 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
  64 epp4 = epp5 + [-1,0] * case_th_side;
  65
  66 kppe = [0,0];
  67 kppd = kppe + [1,0] * keeper_inner_width;
  68 kppc = kppd + [0,1] * keeper_th_z;
  69 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
  70 kppf = kppe - [0,1] * keeper_inner_height;
  71 kppa = [ kppb[0], kppf[1] ];
  72
  73 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
  74 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
  75 lpp12 = [ epp4[0] + lid_lip,   lpp11[1] ];
  76 lpp13 = [ lpp12[0],            lpp12[1] + lid_lip ];
  77
  78 bppM = epp4 + [0,1] * lid_gap_z;
  79 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
  80 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
  81 bppS = [ epp1[0], bppR[1] ];
  82 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
  83 bppP = bppQ + [0,1] * lid_buttoncover_gap;
  84 bppO = [ bppN[0], bppP[1] ];
  85
  86 module rectfromto(a,b) {
  87   ab = b - a;
  88   translate([min(a[0], b[0]), min(a[1], b[1])])
  89     square([abs(ab[0]), abs(ab[1])]);
  90 }
  91 module circleat(c,r) { translate(c) circle(r); }
  92
  93 module KeeperProfile(){
  94   polygon([kppe, kppd, kppc, kppb, kppa, kppf]);
  95 }
  96
  97 module EdgeProfile(){
  98   difference(){
  99     hull(){
 100       translate(epp3) square(case_th_bottom*2, center=true);
 101       circleat(epp2o, r=case_th_bottom);
 102       circleat(epp1, r=case_th_side);
 103       rectfromto(epp0, epp4);
 104     }
 105     polygon([ epp5 + [0,10],
 106               epp1,
 107               epp2i,
 108               epp3 + [10,0] ]);
 109   }
 110 }
 111
 112 module LidEdgeProfile(){
 113   polygon([ lpp10,
 114             lpp11,
 115             lpp12,
 116             lpp13,
 117             lpp13 + [10, 0],
 118             lpp10 + [10, 0]
 119             ]);
 120   intersection(){
 121     circleat(lpp12, r=lid_lip);
 122     rectfromto( lpp12 + [-10,   0],
 123                 lpp12 + [+10, +10] );
 124   }
 125 }
 126
 127 module ButtonPlan(){
 128 }
 129
 130 module CaseBase_rhsflip(yn=[0,1]) {
 131   for (rhs=yn) {
 132     translate([phone_width/2, 0, 0])
 133       mirror([rhs,0,0])
 134       translate([-phone_width/2, 0, 0])
 135       children();
 136   }
 137 }
 138
 139 module CaseBase_botflip() {
 140   for (bot=[0,1]) {
 141     translate([0, -phone_height/2, 0])
 142       mirror([0, bot, 0])
 143       translate([0, phone_height/2, 0])
 144       children();
 145   }
 146 }
 147
 148 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
 149   // sides
 150   CaseBase_rhsflip(){
 151     translate([0, -phone_cnr_rad, 0])
 152       rotate([90,0,0])
 153       linear_extrude(height = phone_height - phone_cnr_rad*2)
 154       children(0);
 155   }
 156   // corners
 157   CaseBase_rhsflip() CaseBase_botflip() {
 158     translate([+1,-1] * phone_cnr_rad)
 159       intersection(){
 160         rotate_extrude()
 161           intersection(){
 162             mirror([1,0,0])
 163               translate([-1,0] * phone_cnr_rad)
 164               children(0);
 165             rectfromto([0,-20],[10,20]);
 166           }
 167         translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
 168           cube([10,10,40]);
 169       }
 170   }
 171   // top and bottom
 172   CaseBase_botflip(){
 173     translate([ phone_width - phone_cnr_rad, 0,0 ])
 174       rotate([90,0,-90])
 175       linear_extrude(height = phone_width - phone_cnr_rad*2)
 176       children(0);
 177   }
 178   // fill
 179   translate([0,0, fill_zstart])
 180     mirror([0,0, fill_downwards])
 181     linear_extrude(height = fill_th)
 182     rectfromto([+1,-1] * phone_cnr_rad,
 183                [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 184 }
 185
 186 module CaseBase(){
 187   AroundEdges(epp3[1], case_th_bottom, 1)
 188     EdgeProfile();
 189 }
 190
 191 module Case(){ ////toplevel
 192   difference(){
 193     union(){
 194       CaseBase();
 195
 196       // ledge (fixed keeper)
 197       intersection(){
 198         rotate([90, 0, 0])
 199           linear_extrude(height = phone_height + phone_cnr_rad * 2)
 200           KeeperProfile();
 201
 202         // outline of the whole case, to stop it protruding
 203         translate([0,0, -25])
 204           linear_extrude(height = 50)
 205           hull()
 206           // CaseBase_rhsflip() // actually, we only care about the LH
 207           CaseBase_botflip()
 208           circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
 209       }
 210     }
 211
 212     // slot for keeper
 213     CaseBase_rhsflip(1)
 214       translate([0, -phone_cnr_rad, 0])
 215       rotate([90, 0, 0])
 216       linear_extrude(height = phone_height + phone_cnr_rad * 2)
 217       minkowski(){
 218         KeeperProfile();
 219         rectfromto([ -keeper_gap_x,    -keeper_gap_z_bot ],
 220                    [ keeper_gap_x_holes,    +keeper_gap_z_top ]);
 221       }
 222
 223     // front camera
 224     CaseBase_rhsflip([1])
 225       mirror([0, 0, 1])
 226       linear_extrude(height = 20)
 227       mirror([0, 1, 0])
 228       rectfromto(camera_pos_tl, camera_pos_br);
 229
 230     // struts (invisible, because they're buried in the case)
 231     for (i= [1 : 1 : case_struts_count]) {
 232       translate([0,
 233                  -phone_height * i / (case_struts_count+1),
 234                  epp2i[1] - case_th_bottom + case_struts_solid_below])
 235         linear_extrude(height= case_th_bottom
 236                        -(case_struts_solid_below+case_struts_solid_above))
 237         rectfromto([               epp2i[0], -0.5 * case_struts_width ],
 238                    [ phone_width - epp2i[0], +0.5 * case_struts_width ]);
 239     }
 240   }
 241 }
 242
 243 module Lid(){ ////toplevel
 244   AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
 245     LidEdgeProfile();
 246 }
 247
 248 module TestLength(){ ////toplevel
 249   intersection(){
 250     Case();
 251     translate([-30, -200, -20])
 252     cube([30 + 15, 250, 40]);
 253   }
 254 }
 255
 256 module TestWidth(){ ////toplevel
 257   intersection(){
 258     Case();
 259     translate([-30, -(phone_height - 25), -20])
 260       mirror([0, 1, 0])
 261       cube([200, 50, 40]);
 262   }
 263 }
 264
 265 module TestLidWidthPrint(){ ////toplevel
 266   rotate([0,180.0])
 267     intersection(){
 268       Lid();
 269       translate([-30, -(phone_height - 25), -20])
 270         mirror([0, 1, 0])
 271         cube([200, 50, 40]);
 272     }
 273 }
 274
 275 module TestCamera(){ ////toplevel
 276   intersection(){
 277     Case();
 278     CaseBase_rhsflip(1)
 279       translate([0,0,-25])
 280       linear_extrude(height = 50)
 281       mirror([0, 1, 0])
 282       rectfromto([-20, -20],
 283                  camera_pos_br + [ 5, 5 ]);
 284   }
 285 }
 286
 287 module OneKeeper(){ ////toplevel
 288   translate([0, -phone_cnr_rad, 0])
 289     rotate([90, 0, 0])
 290     linear_extrude(height = phone_height - phone_cnr_rad * 2)
 291     KeeperProfile();
 292 }
 293
 294 module OneKeeperPrint(){ ////toplevel
 295   rotate([0,180,0])
 296     OneKeeper();
 297 }
 298
 299 module Keeper(){ ////toplevel
 300   CaseBase_rhsflip()
 301     OneKeeper();
 302 }
 303
 304 module DemoProfiles(){ ////toplevel
 305   LidEdgeProfile();
 306   %EdgeProfile();
 307   KeeperProfile();
 308
 309   color("blue") rectfromto(bppM, bppO);
 310   color("red") {
 311     rectfromto(bppQ, [ bppS[0], bppQ[1] - 0.1]);
 312     rectfromto(bppR, [ bppS[0], bppQ[1] - 0.1]);
 313   }
 314 }
 315
 316 //EdgeProfile();
 317 //KeeperProfile();
 318 //CaseBase();
 319 //%Case();
 320 //Keeper();
 321 //LidEdgeProfile();
 322 //KeeperProfile();
 323 //DemoProfiles();