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.
15 button_cutout_depth = 9;
17 phone_edge_thick = 9.0;
18 phone_total_thick = 12.0;
19 phone_backside_slope_inner = 1.5; // larger means shallower
20 phone_backside_slope_outer = 1.0; // larger means shallower
22 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
23 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
25 jack_pos = [ 13.92, 7.96 ];
26 jack_dia = 9.1 + .5; // some jack I had lying around
28 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
29 noisecancelmic_dia = 1.75;
31 fingerpushhole_dias = [ 15, 18 ];
33 rearspeaker_pos_bl = [ 12.64, 18.72 ];
34 rearspeaker_size = [ 3.76, 7.36 ];
36 microusb_above = 3.27 - 0.25;
38 microusb_width = 16.12 + 0.25;
45 case_struts_count = 6;
46 case_struts_solid_below = 1.00;
47 case_struts_solid_above = 0.75;
48 case_struts_width = 0.10;
52 keeper_inner_width = 2.75;
53 keeper_inner_height = 2.75;
54 keeper_slant_slope = 2; // larger means steeper
56 keeper_gap_z_top = 0.25;
57 keeper_gap_z_bot = 0.75;
59 keeper_gap_x_holes = 0.75;
61 keeper_side = 0; // 0 = lhs; 1 = rhs
72 foldover_lever_gap = 0.50;
74 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
75 hingescrew_shaft_len = 12;
76 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
77 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
78 hingescrew_head_th = 1.38 + 0.75;
79 hingescrew_head_dia = 3.92;
80 lever_cover_th = 0.75;
87 buttonishleg_default_l_is_fudge = 10;
89 hinge_base_slope = 1.5; // bigger is steeper
91 strut_min_at_end = 1.5;
94 hinge_x_postscrew_gap = 0.75;
95 hinge_x_arms_gap = 0.35;
96 hinge_r_arms_gap = 0.55;
98 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
102 catch_thickness = 1.0;
103 catch_side_gap = 0.75; // each side
107 catch_finger_height = 1.5;
108 catch_finger_depth = 2.5;
110 // ---------- calculated ----------
112 phone_width = (phone + bumper*2)[0];
113 phone_height = (phone + bumper*2)[1];
115 inside_br = [phone_width, -phone_height];
117 //echo(camera_pos_tl + bumper,
118 // camera_pos_br + bumper);
120 // ----- could be changed -----
121 lid_buttoncover_gap = lid_gap_x;
122 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
124 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
126 //lid_lip_overlap_width xxx bad name = ;
127 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
130 epp1 = [0, -phone_edge_thick];
131 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
132 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
133 epp3 = epp2i + [10, 0];
134 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
135 epp4 = epp5 + [-1,0] * case_th_side;
138 kppd = kppe + [1,0] * keeper_inner_width;
139 kppc = kppd + [0,1] * keeper_th_z;
140 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
141 kppf = kppe - [0,1] * keeper_inner_height;
142 kppa = [ kppb[0], kppf[1] ];
144 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
145 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
147 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
149 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
150 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
154 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
155 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
156 bppS = [ epp1[0], bppR[1] ];
157 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
158 bppP = bppQ + [0,1] * lid_buttoncover_gap;
159 bppO = [ bppN[0], bppP[1] ];
160 bppL = lpp10 + [5,0];
161 bppK = [ bppL[0], bppN[1] ];
162 bppJ = [ bppN[0], bppL[1] ];
165 hp_rn = hingescrew_nut_dia/2;
166 hp_r2_min = hp_rn + lever_cover_th;
167 hp_rs = hingescrew_shaft_dia/2;
168 hp_r1_min = hp_rs + hingemount_th;
170 hp_r1 = max(hp_r1_min, hp_r2_min);
174 hppS = epp2o + [0,-1] * case_th_bottom;
175 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
177 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
178 0.5 * (hppU + hppS)[1] ];
179 hppT = [ hppM[0], hppU[1] - hp_r1 ];
180 hppB = hppT + [0,-1] * hp_k;
182 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
183 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
184 hppE = [ hppE_x, hppE_y ];
186 // hinge elevation x coords
188 hingescrew_portion_len =
189 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
191 hex20 = max(epp2o[0],
193 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
194 hex21 = hex20 + hingescrew_portion_len;
195 hex22 = hex21 + hinge_x_gap;
196 hex23 = hex22 + hingescrew_portion_len
197 - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
198 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
199 echo(hex20, hex21, hex22, hex23, hex24);
200 echo(hingescrew_portion_len);
204 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
205 cppA = cppJ + [lid_gap_x, -lid_gap_z];
206 cppB = [ epp0[0], cppA[1] ];
207 cppP = [ epp4[0], cppJ[1] ];
209 cppS = cppJ + [0,-1] * catch_len;
210 cppD = [ cppA[0], cppS[1] + catch_slop ];
211 cppC = [ cppB[0], cppD[1] ];
212 cppT = cppS + [1,0] * catch_depth;
213 cppU = cppT + [0,-1] * catch_height;
214 cppV = [ cppS[0], cppU[1] - catch_depth ];
216 cppR = 0.5*(cppP + cppJ);
218 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
220 cppV[1] - (catch_finger_height - cp_rQ) ];
221 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
223 // ---------- modules ----------
225 module KeeperProfile(slant=0){
226 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
227 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
230 module EdgeProfile(){
233 translate(epp3) square(case_th_bottom*2, center=true);
234 circleat(epp2o, r=case_th_bottom);
235 circleat(epp1, r=case_th_side);
236 rectfromto(epp0, epp4);
238 polygon([ epp5 + [0,10],
245 module LidEdgeProfile(){
254 circleat(lpp12, r=lp_r12);
255 rectfromto( lpp12 + [-10, 0],
256 lpp12 + [+10, +10] );
260 module ButtonCoverProfile(){
262 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
270 module ButtonPlan(l, deep, cut){
272 (cut ? 0 : lid_buttoncover_gap);
275 (deep ? lid_buttoncover_overlap : 0);
277 C = [0,0]; // by definition
281 B0 = C + [0,-1] * button_cutout_depth;
282 B1 = B0 + [0,1] * epsilon;
284 r0 = 0.5 * (T[1] - B0[1]);
285 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
286 H = A + [0,-1] * delta;
292 E1 = E0 + [1,0] * epsilon;
294 I0 = [ E0[0], H[1] ];
295 I1 = [ E1[0], H[1] ];
298 for (m=[0,1]) mirror([m,0])
299 circleat(H, r0 - epsilon);
301 for (m=[0,1]) mirror([m,0]) {
311 circleat(D, r0 + epsilon);
316 module CatchCatchProfile(){
318 for (c=[ cppR, cppQ ])
322 circleat(lpp12, lp_r12);
323 circleat(lpp12 + [5,0], lp_r12);
324 rectfromto(cppP, cppP + [5,0.1]);
326 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
329 module CatchCutProfile(){
341 module Flip_rhs(yn=[0,1]) {
343 translate([phone_width/2, 0, 0])
344 mirror([$rhsflip,0,0])
345 translate([-phone_width/2, 0, 0])
350 module Flip_bot(yn=[0,1]) {
352 translate([0, -phone_height/2, 0])
353 mirror([0, $botflip, 0])
354 translate([0, phone_height/2, 0])
359 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
362 translate([0, -phone_cnr_rad, 0])
364 linear_extrude(height = phone_height - phone_cnr_rad*2)
368 Flip_rhs() Flip_bot() {
369 translate([+1,-1] * phone_cnr_rad)
374 translate([-1,0] * phone_cnr_rad)
376 rectfromto([0,-20],[10,20]);
378 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
384 translate([ phone_width - phone_cnr_rad, 0,0 ])
386 linear_extrude(height = phone_width - phone_cnr_rad*2)
390 translate([0,0, fill_zstart])
391 mirror([0,0, fill_downwards])
392 linear_extrude(height = fill_th)
393 rectfromto([+1,-1] * phone_cnr_rad,
394 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
397 module CaseAperture(pos, dia, $fn) {
399 translate([ pos[0] + bumper[0],
402 rotate([-90, theta, 0])
403 cylinder(r = dia/2 / cos(theta),
407 module SideButton(y, y_ref_sign, l){
409 // +1 measured from top of actual phone to top of button
410 // -1 measured from bottom of actual phone to bottom of button
411 // 0 y is centre of button in coordinate system
413 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
414 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
417 translate([0, eff_y, 0])
421 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
422 $button_leg_only = true;
423 SideButton(y, y_ref_sign, l) children();
427 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
428 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
429 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
430 Flip_rhs( ) LidButtonishLeg(14, -1) children();
431 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
434 module Struts(x_start, z_min, th){
435 // if th is negative, starts at z_min and works towards -ve z
436 // and object should then be printed other way up
437 for (i= [1 : 1 : case_struts_count]) {
441 mirror([0,0, th<0 ? 1 : 0])
443 -phone_height * i / (case_struts_count+1),
444 case_struts_solid_below])
445 linear_extrude(height= abs(th)
446 -(case_struts_solid_below+case_struts_solid_above))
447 rectfromto([ x_start, -0.5 * case_struts_width ],
448 [ phone_width - x_start, +0.5 * case_struts_width ]);
452 module OrdinaryRearAperture(rhs,bot, pos){
453 Flip_rhs(rhs) Flip_bot(bot)
456 translate(pos + bumper)
464 linextr(-epp2i[0], 60)
465 translate([0.5 * phone_width, 0, 0])
466 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
467 [+microusb_width/2, epp0[1] + -microusb_above]);
471 module OrdinaryRearApertures(){
473 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
474 rectfromto(-rearspeaker_gap,
475 rearspeaker_size + rearspeaker_gap);
477 // finger hole to remove phone
478 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
480 scale(fingerpushhole_dias)
484 module RearCameraAperture(){
487 linear_extrude(height = 20)
490 rectfromto(camera_pos_tl, camera_pos_br);
493 module HingeLidProfile(){
495 circleat(hppT, hp_r1);
496 circleat(lpp12, lp_r12);
504 module HingeBaseProfile(){
507 circleat(hppB, hp_r1);
508 circleat(hppE, hp_r1);
509 circleat(epp2o, case_th_bottom);
510 circleat(hppB + [10,0], hp_r1);
512 polygon([epp5, epp1, epp2i, epp3, bppL]);
516 module HingeLeverOuterProfile(){
518 circleat(hppT, hp_r2);
519 circleat(hppB, hp_r2);
523 module HingeLeverInnerProfile(){
524 for (c = [hppT, hppB]) {
527 for (y=[0, c[1] - hppM[1]])
534 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
535 translate(hinge_origin)
537 translate(-hinge_origin)
541 module HingePortion(x0,x1){
542 Flip_rhs() Flip_bot(1)
546 linear_extrude(height=x1-x0)
550 module CatchPortion(width){
551 translate([phone_width/2, 0,0])
553 linextr(-width/2, width/2)
558 AroundEdges(epp3[1], case_th_bottom, 1)
562 module Case(){ ////toplevel
567 // ledge (fixed keeper)
568 Flip_rhs(1-keeper_side) intersection(){
570 linear_extrude(height = phone_height + phone_cnr_rad * 2)
573 // outline of the whole case, to stop it protruding
574 translate([0,0, -25])
575 linear_extrude(height = 50)
578 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
582 HingePortion(hex20, hex21) HingeBaseProfile();
586 Flip_rhs(keeper_side)
587 translate([0, -phone_cnr_rad, 0])
589 linear_extrude(height = phone_height + phone_cnr_rad * 2)
592 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
593 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
597 RearCameraAperture();
599 // struts (invisible, because they're buried in the case)
600 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
605 if (!($button_leg_only && enable_support))
608 linear_extrude(height= 20)
609 ButtonPlan($button_l, 0,1);
610 if ($button_leg_only)
612 translate([phone_width/2, -400, kppe[1]])
613 mirror([1-abs($rhsflip - keeper_side),0,0])
614 cube([400, 800, 50]);
617 translate([-400, -400, kppd[1]])
621 translate([0,0, -bppR[0]])
622 linear_extrude(height= 20)
623 ButtonPlan($button_l, 1,1);
627 // apertures along top edge
628 CaseAperture(jack_pos, jack_dia, 8);
630 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
632 OrdinaryRearApertures();
636 // gaps for the lid's hinge arms
637 HingePortion(hex20 - hinge_x_arms_gap,
638 hex21 + hinge_x_arms_gap)
641 circle(r= hinge_r_arms_gap, $fn= 8);
644 // screw holes in the hinge arms
648 CatchPortion(catch_width + catch_side_gap*2)
653 module Lid(){ ////toplevel
656 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
664 linear_extrude(height= 20)
665 ButtonPlan($button_l, 1,0);
667 translate([0,0,-100])
668 linear_extrude(height= 200)
669 ButtonCoverProfile();
674 HingePortion(hex20, hex21) HingeLidProfile();
677 CatchPortion(catch_width)
680 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
682 // screw holes in the hinge arms
687 module HingeLever(){ ////toplevel
689 // outer body, positive
690 HingePortion(hex22, hex22 + phone_width/2)
691 HingeLeverOuterProfile();
693 // space for the screws
694 HingePortion(hex23, hex24)
695 HingeLeverInnerProfile();
697 // bores for the screws
700 // space for the charging cable
702 Flip_hinge() MicroUSB();
706 module HingeLeverPrint(){ ////toplevel
711 module TestSelectLength(){
712 translate([-30, -200, -20])
713 cube([30 + 15, 250, 40]);
716 module TestLength(){ ////toplevel
723 module TestLengthRight(){ ////toplevel
731 module TestSelectWidth(){
732 translate([-30, -(phone_height - 25), -20])
737 module TestWidth(){ ////toplevel
744 module TestLidWidthPrint(){ ////toplevel
745 rotate([0,180.0]) intersection(){
751 module TestSelectRearAperture(){
755 cube([42, 2, 1], center=true);
759 module TestSelectCamera(){
761 TestSelectRearAperture()
762 RearCameraAperture();
763 cube([0.1, 50, 0.1]);
767 module TestSelectOrdinaryRearApertures(){
768 TestSelectRearAperture()
769 OrdinaryRearApertures();
772 module TestCamera(){ ////toplevel
779 module TestLidByCamera(){ ////toplevel
786 module TestLidByCameraPrint(){ ////toplevel
787 rotate([180,0,0]) TestLidByCamera();
790 module DemoByCamera(){ ////toplevel
791 color("blue") TestLidByCamera();
792 color("red") TestCamera();
795 module OneKeeper(){ ////toplevel
796 translate([0, -phone_cnr_rad, 0])
798 linear_extrude(height = phone_height - phone_cnr_rad * 2)
802 module OneKeeperPrint(){ ////toplevel
807 module LidPrint(){ ////toplevel
812 module TestSelectFrame(){
813 include = [1,-1] * (epp2i[0] + 4);
816 cube(1000, center=true);
817 translate([0,0, -100])
818 linear_extrude(height=200)
819 rectfromto(include, inside_br - include);
823 module TestFrameCase(){ ////toplevel
829 TestSelectOrdinaryRearApertures();
834 module TestFrameLidPrint(){ ////toplevel
835 rotate([0,180,0]) intersection(){
841 module ButtonPlanForDemo(z, deep, cut){
843 ButtonPlan(8, deep, cut);
846 module HingeScrews(){
847 Flip_rhs() Flip_bot(1){
848 for (c= [ hppT, hppB ])
854 cylinder( r= hingescrew_shaft_dia/2,
855 h = hingescrew_shaft_len+0.2 );
858 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
863 module DemoFrame(){ ////toplevel
864 color("red") TestFrameCase();
865 color("blue") intersection(){ Lid(); TestSelectFrame(); }
866 color("black") HingeScrews();
870 module DemoHingedFrame(){ ///toplevel
871 color("red") TestFrameCase();
872 translate([0,0, -2*hp_k])
873 color("blue") intersection(){ Lid(); TestSelectFrame(); }
876 color("orange") HingeLever();
877 color("black") HingeScrews();
881 module DemoHinge(){ ////toplevel
883 translate([0,0, -hp_k*3])
887 module DemoProfiles(){ ////toplevel
891 translate([0,0,-1]) color("black") KeeperProfile(1);
897 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
899 color("blue") ButtonCoverProfile();
901 rectfromto(bppQ, demopoint_QR);
902 rectfromto(bppR, demopoint_QR);
907 color("black") ButtonPlanForDemo(-2, 0,1);
908 color("red" ) ButtonPlanForDemo(-4, 1,1);
909 color("blue") ButtonPlanForDemo(-6, 1,0);
912 translate([0, -30]) {
915 color("blue") HingeLidProfile();
916 color("red") HingeBaseProfile();
917 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
918 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
921 translate([20,-30]) {
924 //translate([0,0,1]) CatchCutProfile();
925 color("blue") CatchCatchProfile();
926 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }