3 // Hard case for Fairphone 2
5 // Copyright 2018 Ian Jackson. There is NO WARRANTY.
6 // See below for full licensing and disclaimer.
10 // 1. You will want to git clone this repository.
12 // 2. Decide about the notification LED aperture. See the variable
13 // led_window_style, below. The default here is "ad-hoc
14 // multi-colour", which can produces a translucent (clear-ish)
15 // window set into the lid, even on a single-nozzle printer.
16 // See "Ad-hoc multi-colour", below.
18 // 3. use "make" to generate the necessary files:
20 // make -j8 fairphone-case.auto.scads `for f in \
26 // ; do echo fairphone-case,$f.auto.stl; done`
28 // 4. Print them. Case and OneKeeperPrint should probably be
31 // For Lid and LidWindowPrint, if you are doing ad-hoc
33 // i. Set up for clear filament
34 // ii. Print LidWindowPrint. Wait for it to finish.
35 // It won't take long. As soon as it finishes, tell
36 // your printer to warm up (so that in fact it does
38 // iii. Leaving the output so far on the printbed, reload
39 // your printer with the main lid colour.
40 // iv. Print LidPrint. You can let this go unattended.
42 // 5. Assemble the hinge. You will need 4x M2 12mm machine screws
43 // and 8x M2 full nuts.
45 // Make sure you get the hinge the right way round. If you're not
47 // openscad fairphone-case,DemoHinge.auto.scad
48 // to see an assembly diagram.
50 // The nuts recess into the hinge. You will want very fine
51 // pliers. As you screw each screw in, add the second nut when
52 // the screw thread emerges from the first - this will be a
53 // locknut. Screw each screw to an appropriate tightness for the
54 // hinge stiffness. You want the lid-side hinge to be stiffer as
55 // that makes closing the case work better.
57 // When you have the stiffness right, tighten the locknuts onto
62 // - To put the phone in, drop its RH side into the RH side of
63 // the case. Then feed the keeper through the small hole.
64 // Feed it right through.
66 // - The optional prop can be used to prop the phone up (in
67 // portrait orientation only right now). See
68 // openscad fairphone-case,DemoPropAngles.auto.scad
70 // Ad-hoc multi-colour
72 // This file is set up to let you make a translucent window using a
73 // single-extruder printer, using a "two print run" technique. This
74 // works well with our Lulzbot TAZ 5 and Aleph Objects' version of
75 // Cura. If you are using a different printer, you may need to
76 // adjust the parameters or try a different technique. In particular,
77 // initial_layer_thick
78 // set so that the window is one layer thick
79 // initial_layer_width
80 // set so that the slicer draws a rectangle around the whole
81 // object, rather than putting a "skirt" or anything inside
83 // If you have a dual-extruder printer, you can set led_window_style
84 // to 2 and do a single print of LidPrint and LidWindowPrint.
86 // Alternatively you can set it to 1 (just a hole) or 0 (no hole).
88 // Thanks to Clare Boothby for the ad-hoc multi-colour technique (and
89 // the parameters for our Lulzbot TAZ 5 and Aleph Objects's Cura).
93 // It might well be possible to adapt this file for other phones.
94 // If you do, let me know how you get on.
97 // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY
99 // Copyright (C)2018 Ian Jackson.
101 // This program for generating a 3D model is free software: you can
102 // redistribute it and/or modify it under the terms of the GNU
103 // General Public License as published by the Free Software
104 // Foundation, either version 3 of the License, or (at your option)
105 // any later version.
107 // This program is distributed in the hope that it will be useful,
108 // but WITHOUT ANY WARRANTY; without even the implied warranty of
109 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
110 // GNU General Public License for more details.
112 // You should have received a copy of the GNU General Public
113 // License along with this program. If not, see
114 // <http://www.gnu.org/licenses/>.
116 // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY
117 // PROTECT YOUR PHONE ! It is your responsibility to decide whether
118 // this case will meet your needs.
122 phone = [ 75.0, 145.0 ];
124 prop_buildout_less = 3;
126 prop_angles = [ 15, 30, 45, 60 ];
128 bumper = [ 0.250, -0.025 ];
129 // ^ One side. Overall size is increased by twice this.
130 // If no bumpers, is the gap around the phone.
134 led_window_style = 3;
136 // 1: simply an opening
137 // 2: opening with separate cover model, for printing in clear (two colour)
138 // 3: like 2 but one-layer window for ad-hoc multi-colour
140 initial_layer_thick = 0.400; // ^ needed for mode 3 only
141 initial_layer_width = 0.750; // ^ needed for mode 3 only
142 multicolour_gap = 0.15; // each side
145 phone_rim_depth = 0.80; // includes allowance for a screen protector
147 button_cutout_depth = 9;
149 phone_edge_thick = 9.0;
150 phone_total_thick = 12.0;
151 phone_backside_slope_inner = 1.5; // larger means shallower
152 phone_backside_slope_outer = 1.0; // larger means shallower
154 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
155 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
157 jack_pos = [ 13.83, 8.485 ];
158 jack_dia = 10.64 + .5; // some jack I had lying around
160 led_pos = [ 13.98, 10.00 ];
162 led_window_ledge = 0.75; // each side
164 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
165 noisecancelmic_dia = 4.00;
167 //fingerpushhole_dias = [ 15, 18 ];
168 fingerpushhole_dias = [];
170 rearspeaker_pos_bl = [ 12.64, 18.72 ];
171 rearspeaker_size = [ 3.76, 7.36 ];
173 microusb_above = 3.27 - 0.25;
174 microusb_below = 0.0;
175 microusb_width = 16.12 + 1.25;
177 case_th_bottom = 2.5;
182 lid_screen_gap_extra = .66;
184 case_struts_count = 6;
185 case_struts_solid_below = 1.00;
186 case_struts_solid_above = 0.75;
187 case_struts_width = 0.10;
191 keeper_inner_width = 2.75;
192 keeper_inner_height = 2.75;
193 keeper_slant_slope = 2; // larger means steeper
195 keeper_gap_z_top = 0.25;
196 keeper_gap_z_bot = 0.75;
198 keeper_gap_x_holes = 0.75;
200 keeper_side = 0; // 0 = lhs; 1 = rhs
207 lid_edgepart_width = 5.0;
208 lid_buttoncover_thick = 1.3;
213 foldover_lever_gap = 0.50;
215 // properties of the hinge fasteners
216 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
217 hingescrew_shaft_len = 12;
218 hingescrew_fasteners_extra_thick = 0.40;
219 // ^ amount of thread protruding if everything was completely nominal
220 // and we are using two nuts
221 hingescrew_nut_access_dia = 4.72 + 0.50;
222 // ^ washer is 4.72 dia
223 // also, want to get pliers or tiny spanner in to do up locknut
224 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
225 hingescrew_nut_thick = 1.93;
226 hingescrew_head_th = 1.38 + 0.75;
227 hingescrew_head_dia = 3.92;
229 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
231 lever_cover_th = 0.75;
233 hingemount_wd = 4.8725;
238 button_l_fudge = 4.4;
239 buttonishleg_default_l_is_fudge = 10;
241 hinge_base_slope = 1.5; // bigger is steeper
243 strut_min_at_end = 1.5;
246 hinge_x_postscrew_gap = 0.75;
247 hinge_x_arms_gap = 0.35;
248 hinge_r_arms_gap = 0.55;
250 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
254 catch_thickness = 1.0;
255 catch_side_gap = 0.75; // each side
259 catch_finger_height = 1.5;
260 catch_finger_depth = 2.5;
262 prop_recess_under = 0.50;
263 prop_recess_slop = 0.200; // each side
268 prop_side_gap = 0.75; // each side
269 prop_lidrecess_behind = 0.75;
270 prop_caserecess_behind = 0.75;
271 prop_caserecess_taper = 0.45; // one side only
273 prop_prong_heel_slope = 0.5;
275 lid_fold_clearance_antislop = 0.5;
277 // ---------- calculated ----------
279 phone_width = (phone + bumper*2)[0];
280 phone_height = (phone + bumper*2)[1];
282 inside_br = [phone_width, -phone_height];
284 prop_prong_h = prop_main_th;
286 //echo(camera_pos_tl + bumper,
287 // camera_pos_br + bumper);
289 // ----- could be changed -----
290 lid_buttoncover_gap = lid_gap_x;
291 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
293 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
295 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
297 //prop_nose_len = case_th_lid - prop_recess_under;
298 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
299 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
302 //lid_lip_overlap_width xxx bad name = ;
303 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
306 epp1 = [0, -phone_edge_thick];
307 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
308 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
309 epp3 = epp2i + [10, 0];
310 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
311 epp4 = epp5 + [-1,0] * case_th_side;
314 kppd = kppe + [1,0] * keeper_inner_width;
315 kppc = kppd + [0,1] * keeper_th_z;
316 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
317 kppf = kppe - [0,1] * keeper_inner_height;
318 kppa = [ kppb[0], kppf[1] ];
320 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
321 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
323 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
324 // exact x posn not very important; must extend past end of keeper
327 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
328 + lid_screen_gap_extra ];
329 // ^ beam theory says to maximise force before contact,
330 // the gap below the `beam' (the lid) must be 1/3
331 // the thickness (ie the lid thickness) if the beam
332 // is solid, or 1/2 if it has a top and bottom only.
333 // ours is mostly solid.
335 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
338 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
339 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
341 case_bottom_z = epp2o[1] - case_th_bottom;
345 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
346 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
347 bppS = [ epp1[0], bppR[1] ];
348 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
349 bppP = bppQ + [0,1] * lid_buttoncover_gap;
350 bppO = [ bppN[0], bppP[1] ];
351 bppL = lpp10 + [5,0];
352 bppK = [ bppL[0], bppN[1] ];
353 bppJ = [ bppN[0], bppL[1] ];
354 bppU = [ bppJ[0], lpp12[1] ];
358 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
360 // notification led aperture
362 nla_r0 = led_aperture/2;
363 nla_r1 = nla_r0 + led_window_ledge;
364 nla_r2 = nla_r1 + multicolour_gap;
366 led_window_style >= 3 ? initial_layer_thick :
367 led_window_style >= 2 ? led_window_ledge : 0;
371 hp_rn = hingescrew_nut_access_dia/2;
372 hp_r2_min = hp_rn + lever_cover_th;
373 hp_rs = hingescrew_shaft_dia/2;
374 hp_r1_min = hp_rs + hingemount_th;
376 hp_r1 = max(hp_r1_min, hp_r2_min);
380 hppS = epp2o + [0,-1] * case_th_bottom;
381 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
383 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
384 0.5 * (hppU + hppS)[1] ];
385 hppT = [ hppM[0], hppU[1] - hp_r1 ];
386 hppB = hppT + [0,-1] * hp_k;
388 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
389 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
390 hppE = [ hppE_x, hppE_y ];
392 // hinge elevation x coords
394 hex20 = max(epp2o[0],
396 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
397 hex21 = hex20 + hingemount_wd;
398 hex22 = hex21 + hinge_x_gap;
399 hex27 = hex20 + hingescrew_shaft_len;
400 hex24 = hex27 + hinge_x_postscrew_gap;
401 hex23 = hex27 - (hingescrew_nut_thick*2
402 + hingescrew_fasteners_extra_thick);
403 hex26 = hex23 + hingescrew_nut_thick * 2/3;
405 echo(hex20, hex21, hex22, hex23, hex24);
406 // 6, 10.8725, 10.9975, 13.74, 18.75
407 module chk(act,exp) {
408 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
409 else echo("ok", act);
417 lid_fold_clearance_skew =
418 (lpp10[1] - hppB[1]) /
419 (lpp10[0] - hppB[0]);
421 echo("SK",lid_fold_clearance_skew);
425 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
426 cppA = cppJ + [lid_gap_x, -lid_gap_z];
427 cppB = [ epp0[0], cppA[1] ];
428 cppP = [ epp4[0], cppJ[1] ];
430 cppS = cppJ + [0,-1] * catch_len;
431 cppD = [ cppA[0], cppS[1] + catch_slop ];
432 cppC = [ cppB[0], cppD[1] ];
433 cppT = cppS + [1,0] * catch_depth;
434 cppU = cppT + [0,-1] * catch_height;
435 cppV = [ cppS[0], cppU[1] - catch_depth ];
437 cppR = 0.5*(cppP + cppJ);
439 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
441 cppV[1] - (catch_finger_height - cp_rQ) ];
442 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
444 // prop recess in case
446 prop_x_pos = phone_width/2;
448 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
450 prc_r1 = prop_end_dia/2;
451 prc_r3 = prc_r1 + prop_recess_slop;
453 prcp2 = [ epp4[0] + prop_buildout_less,
456 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
458 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
459 epp2i[1] - prc_r3 - prop_recess_under];
461 // prop recess in lid
463 prl_r10 = prop_end_dia/2;
464 prl_r10o = prl_r10 + prop_recess_slop;
466 prlp10 = lpp10 + [1,1] * prl_r10o
467 + [1,0] * prop_lidrecess_behind
468 + [0,1] * prop_recess_under;
473 $prpp11 = [0, prop_taper_len];
477 // ---------- modules ----------
479 module AdhocMultiprintFrame(phase, z0, zs) {
480 // from z0 to z0 + zs*layer
481 extra = phase * (initial_layer_width + multicolour_gap) + 5;
482 xextra = extra + -epp4[0];
483 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
484 yextra = extra + -epp4[0];
485 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
486 p0 = [ xrange[0], yrange[0] ];
487 p1 = [ xrange[1], yrange[1] ];
490 mirror([0,0, zs<0 ? 1 : 0])
491 linear_extrude(height= initial_layer_thick)
493 rectfromto(p0 - [1,1] * initial_layer_width,
494 p1 + [1,1] * initial_layer_width);
499 module KeeperProfile(slant=0){
500 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
501 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
504 module EdgeProfile(){
507 translate(epp3) square(case_th_bottom*2, center=true);
508 circleat(epp2o, r=case_th_bottom);
509 circleat(epp1, r=case_th_side);
510 rectfromto(epp0, epp4);
512 polygon([ epp5 + [0,10],
519 module LidEdgeProfile(){
530 circleat(lpp12, r=lp_r12);
531 rectfromto( lpp12 + [-10, 0],
532 lpp12 + [+10, +10] );
536 module LidEdgeFoldClearanceProfile(){
537 translate([-lid_fold_clearance_antislop, 0])
546 module ButtonCoverProfile(){
548 polygon(concat([ bppM, bppP, bppO, bppJ ],
549 (enable_support && !$button_suppress_over_keeper
550 ? [ bppU, bppV, bppW ] : []),
559 module ButtonPlan(l, deep, cut){
561 (cut ? 0 : lid_buttoncover_gap);
564 (deep ? lid_buttoncover_overlap : 0);
566 C = [0,0]; // by definition
570 B0 = C + [0,-1] * button_cutout_depth;
571 B1 = B0 + [0,1] * epsilon;
573 r0 = 0.5 * (T[1] - B0[1]);
574 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
575 H = A + [0,-1] * delta;
581 E1 = E0 + [1,0] * epsilon;
583 I0 = [ E0[0], H[1] ];
584 I1 = [ E1[0], H[1] ];
587 for (m=[0,1]) mirror([m,0])
588 circleat(H, r0 - epsilon);
590 for (m=[0,1]) mirror([m,0]) {
600 circleat(D, r0 + epsilon);
605 module CatchCatchProfile(){
607 for (c=[ cppR, cppQ ])
611 circleat(lpp12, lp_r12);
612 circleat(lpp12 + [5,0], lp_r12);
613 rectfromto(cppP, cppP + [5,0.1]);
615 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
618 module CatchCutProfile(){
630 module Flip_rhs(yn=[0,1]) {
632 translate([phone_width/2, 0, 0])
633 mirror([$rhsflip,0,0])
634 translate([-phone_width/2, 0, 0])
639 module Flip_bot(yn=[0,1]) {
641 translate([0, -phone_height/2, 0])
642 mirror([0, $botflip, 0])
643 translate([0, phone_height/2, 0])
648 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
651 translate([0, -phone_cnr_rad, 0])
653 linear_extrude(height = phone_height - phone_cnr_rad*2)
657 Flip_rhs() Flip_bot() {
658 translate([+1,-1] * phone_cnr_rad)
663 translate([-1,0] * phone_cnr_rad)
665 rectfromto([0,-20],[10,20]);
667 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
673 translate([ phone_width - phone_cnr_rad, 0,0 ])
675 linear_extrude(height = phone_width - phone_cnr_rad*2)
679 translate([0,0, fill_zstart])
680 mirror([0,0, fill_downwards])
681 linear_extrude(height = fill_th)
682 rectfromto([+1,-1] * phone_cnr_rad,
683 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
686 module CaseAperture(pos, dia, $fn) {
688 translate([ pos[0] + bumper[0],
691 rotate([-90, theta, 0])
692 cylinder(r = dia/2 / cos(theta),
696 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
698 // +1 measured from top of actual phone to top of button
699 // -1 measured from bottom of actual phone to bottom of button
700 // 0 y is centre of button in coordinate system
702 $button_suppress_over_keeper= suppress_over_keeper;
703 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
704 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
707 translate([0, eff_y, 0])
711 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
712 $button_leg_only = true;
713 SideButton(y, y_ref_sign, l) children();
717 Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
718 Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
719 Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
720 Flip_rhs( ) LidButtonishLeg(14, -1) children();
721 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
724 module Struts(x_start, z_min, th){
725 // if th is negative, starts at z_min and works towards -ve z
726 // and object should then be printed other way up
727 for (i= [1 : 1 : case_struts_count]) {
731 mirror([0,0, th<0 ? 1 : 0])
733 -phone_height * i / (case_struts_count+1),
734 case_struts_solid_below])
735 linear_extrude(height= abs(th)
736 -(case_struts_solid_below+case_struts_solid_above))
737 rectfromto([ x_start, -0.5 * case_struts_width ],
738 [ phone_width - x_start, +0.5 * case_struts_width ]);
742 module OrdinaryRearAperture(rhs,bot, pos){
743 Flip_rhs(rhs) Flip_bot(bot)
746 translate(pos + bumper)
754 linextr(-epp2i[0], 60)
755 translate([0.5 * phone_width, 0, 0])
756 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
757 [+microusb_width/2, epp0[1] + -microusb_above]);
761 module OrdinaryRearApertures(){
763 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
764 rectfromto(-rearspeaker_gap,
765 rearspeaker_size + rearspeaker_gap);
767 // finger hole to remove phone
768 if (len(fingerpushhole_dias))
769 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
771 scale(fingerpushhole_dias)
775 module RearCameraAperture(){
778 linear_extrude(height = 20)
781 rectfromto(camera_pos_tl, camera_pos_br);
784 module HingeLidProfile(){
786 circleat(hppT, hp_r1);
787 circleat(lpp12, lp_r12);
795 module HingeBaseProfile(){
798 circleat(hppB, hp_r1);
799 circleat(hppE, hp_r1);
800 circleat(epp2o, case_th_bottom);
801 circleat(hppB + [10,0], hp_r1);
803 polygon([epp5, epp1, epp2i, epp3, bppL]);
807 module HingeLeverOuterProfile(){
809 circleat(hppT, hp_r2);
810 circleat(hppB, hp_r2);
814 module HingeLeverInnerProfile(){
816 c = s > 0 ? hppT : hppB;
819 rotate(s<0 ? -40 : 0)
828 module HingeLeverNutProfile(){
829 for (c= [hppB, hppT]) {
831 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
835 module Flip_hinge(doflip=1){
836 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
837 translate(hinge_origin)
838 rotate([doflip*180,0,0])
839 translate(-hinge_origin)
843 module HingePortion(x0,x1){
844 Flip_rhs() Flip_bot(1)
848 linear_extrude(height=x1-x0)
852 module CatchPortion(width){
853 translate([phone_width/2, 0,0])
855 linextr(-width/2, width/2)
860 AroundEdges(epp3[1], case_th_bottom, 1)
864 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
866 module PropProfileAssignments(gamma){
867 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
869 p = phone_height + prlp10[0] - hppB[0];
872 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
874 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
875 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
877 $prp_theta = 90 - $prp_alpha;
878 beta = 180 - $prp_alpha - gamma;
881 //echo("abc", a,b,c);
883 v1 = [ [ cos(psi), -sin(psi) ], // x
884 [ sin(psi), cos(psi) ] ]; // y
886 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
889 $prp_r11 = prop_main_th/2;
891 $prpp1 = $prpp7 + [1,0] *
892 // this is approximate, but will do
893 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
896 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
897 $prpp12 = $prpp3 + v1[0] *
898 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
899 $prp_r8 = prop_main_th;
900 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
902 $prpp5 = [ $prpp12[0] - $prp_r5,
903 $prpp3[1] - prop_prong_h + $prp_r5 ];
904 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
905 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
906 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
907 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
912 module PropProfile(gamma, cut=0, rot=0){ ////toplevel
913 PropProfileAssignments(gamma){
915 //#circleat($prpp3,1);
916 //#circleat($prpp12,1);
923 polygon([[-20,-0], [20,20], [0,0]]);
925 rectfromto($prpp6, $prpp9);
926 translate($prpp5) intersection(){
928 polygon([[-10,-10], [0,0], [10,0]]);
930 rectfromto($prpp12 + [0,-0.1], $prpp3);
933 circleat($prpp1, $prp_r1);
934 rectfromto($prpp12 + [0,-0.1], $prpp3);
938 rotate([0,0, rot*-$prp_theta]){
940 extra = cut ? prop_recess_slop : 0;
941 rectfromto($prpp6, $prpp9);
942 circleat($prpp11, $prp_r11 + extra);
943 circleat($prpp10, $prp_r10 + extra);
949 module PropAggregateProfile(){
950 for (angle = prop_angles)
951 PropProfile(angle, 0,0);
954 module Prop(){ ////toplevel
955 hw = prop_main_width/2;
957 PropAggregateProfile();
960 module Case(){ ////toplevel
965 // ledge (fixed keeper)
966 Flip_rhs(1-keeper_side) intersection(){
968 linear_extrude(height = phone_height + phone_cnr_rad * 2)
971 // outline of the whole case, to stop it protruding
972 translate([0,0, -25])
973 linear_extrude(height = 50)
976 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
980 HingePortion(hex20, hex21) HingeBaseProfile();
982 // buildout for prop recess
983 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
984 linextr(case_bottom_z, epp2i[1])
987 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
989 r = epp2o[0] - prcp2[0]);
994 Flip_rhs(keeper_side)
995 translate([0, -phone_cnr_rad, 0])
997 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1000 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1001 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1005 RearCameraAperture();
1007 // struts (invisible, because they're buried in the case)
1008 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1013 if (!($button_leg_only && enable_support))
1015 translate([0,0,-10])
1016 linear_extrude(height= 20)
1017 ButtonPlan($button_l, 0,1);
1018 if ($button_leg_only)
1020 translate([phone_width/2, -400, kppe[1]])
1021 mirror([1-abs($rhsflip - keeper_side),0,0])
1022 cube([400, 800, 50]);
1023 if (enable_support && !$button_suppress_over_keeper)
1025 translate([-400, -400, kppd[1]])
1027 cube([800,800,100]);
1029 translate([0,0, -bppR[0]])
1030 linear_extrude(height= 20)
1031 ButtonPlan($button_l, 1,1);
1036 // apertures along top edge
1037 CaseAperture(jack_pos, jack_dia, 8);
1039 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1041 OrdinaryRearApertures();
1045 // gaps for the lid's hinge arms
1046 HingePortion(hex20 - hinge_x_arms_gap,
1047 hex21 + hinge_x_arms_gap)
1050 circle(r= hinge_r_arms_gap, $fn= 8);
1053 // screw holes in the hinge arms
1057 CatchPortion(catch_width + catch_side_gap*2)
1062 translate([prop_x_pos,0,0])
1065 linextr(-prop_recess_hw, +prop_recess_hw)
1067 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1068 circleat(prcp1 + 20*d,
1074 module LidAdhocMultiprintFrame(phase){
1075 if (led_window_style >= 3) {
1076 AdhocMultiprintFrame(phase, lpp13[1], -1);
1080 module LidAroundEdges(){
1081 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1085 module Lid(){ ////toplevel
1086 skew_centre = [0, lpp11[0], lpp11[1]];
1093 translate(skew_centre)
1094 multmatrix([[ 1, 0, 0, 0 ],
1095 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1098 translate(-skew_centre)
1100 LidEdgeFoldClearanceProfile();
1107 translate([0,0,-10])
1108 linear_extrude(height= 20)
1109 ButtonPlan($button_l, 1,0);
1111 translate([0,0,-100])
1112 linear_extrude(height= 200)
1113 ButtonCoverProfile();
1118 HingePortion(hex20, hex21) {
1124 CatchPortion(catch_width)
1125 CatchCatchProfile();
1127 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1129 // screw holes in the hinge arms
1133 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1136 linextr(-prop_recess_hw, +prop_recess_hw)
1138 for (pa = prop_angles)
1139 PropProfile(pa, 1,1);
1141 // notification led aperture
1142 if (led_window_style)
1143 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1144 translate([0,0,-10])
1145 cylinder(r=nla_r0, h=20);
1146 if (led_window_style >= 2)
1147 translate([0,0, -nla_t])
1148 cylinder(r=nla_r2, height=20);
1153 LidAdhocMultiprintFrame(1);
1156 module HingeLever(){ ////toplevel
1158 // outer body, positive
1159 HingePortion(hex22, hex22 + phone_width/2)
1160 HingeLeverOuterProfile();
1162 // space for the screws
1163 HingePortion(hex26, hex24)
1164 HingeLeverInnerProfile();
1166 // recesses for the nuts
1167 HingePortion(hex23, hex26+1)
1168 HingeLeverNutProfile();
1170 // bores for the screws
1173 // space for the charging cable
1175 Flip_hinge() MicroUSB();
1179 module LidWindow(){ ////toplevel
1180 translate([led_pos[0], -led_pos[1], lpp13[1]])
1182 cylinder(r= nla_r1, h=nla_t);
1183 LidAdhocMultiprintFrame(0);
1186 module LidWindowPrint(){ ////toplevel
1191 module DemoLidWindowSelect(){
1192 translate([led_pos[0], led_pos[1], -100]) {
1193 translate([0, -30, 0]) cube([400, 400, 200]);
1197 module DemoLidWindow(){ ////toplevel
1200 translate([0,40,0]){
1201 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1202 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1206 module HingeLeverPrint(){ ////toplevel
1208 translate([-phone_width/2, phone_height, 0])
1212 module TestSelectLength(){
1213 translate([-30, -200, -20])
1214 cube([30 + 15, 250, 40]);
1217 module TestLength(){ ////toplevel
1224 module TestLengthRight(){ ////toplevel
1232 module TestSelectWidth(){
1233 translate([-30, -(phone_height - 25), -20])
1235 cube([200, 50, 40]);
1238 module TestWidth(){ ////toplevel
1245 module TestLidWidthPrint(){ ////toplevel
1246 rotate([0,180.0]) intersection(){
1252 module TestSelectRearAperture(){
1255 translate([20, 0,0])
1256 cube([42, 2, 1], center=true);
1260 module TestSelectCamera(){
1262 TestSelectRearAperture()
1263 RearCameraAperture();
1264 cube([0.1, 50, 0.1]);
1268 module TestSelectOrdinaryRearApertures(){
1269 TestSelectRearAperture()
1270 OrdinaryRearApertures();
1273 module TestCamera(){ ////toplevel
1280 module TestLidByCamera(){ ////toplevel
1287 module TestLidByCameraPrint(){ ////toplevel
1288 rotate([180,0,0]) TestLidByCamera();
1291 module DemoByCamera(){ ////toplevel
1292 color("blue") TestLidByCamera();
1293 color("red") TestCamera();
1296 module OneKeeper(){ ////toplevel
1297 translate([0, -phone_cnr_rad, 0])
1299 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1303 module OneKeeperPrint(){ ////toplevel
1308 module LidPrint(){ ////toplevel
1313 module TestSelectFrame(){
1314 include = [1,-1] * (epp2i[0] + 4);
1317 cube(1000, center=true);
1318 translate([0,0, -100])
1319 linear_extrude(height=200)
1320 rectfromto(include, inside_br - include);
1324 module TestSelectLidFrame(){
1326 translate([led_pos[0], -led_pos[1], -50])
1327 cylinder(r= nla_r2+3, h=100);
1330 module TestFrameCase(){ ////toplevel
1336 TestSelectOrdinaryRearApertures();
1341 module TestSelectTopApertures(){
1342 translate([-100, -35, -100])
1343 cube([400, 100, 200]);
1344 LidAdhocMultiprintFrame(0);
1345 LidAdhocMultiprintFrame(1);
1348 module TestTopApertures(){ ////toplevel
1352 TestSelectTopApertures();
1356 module TestLidTopAperturesPrint(){ ////toplevel
1357 rotate([0,180,0]) intersection(){
1359 TestSelectLidFrame();
1360 TestSelectTopApertures();
1364 module TestLidWindowTopAperturesPrint(){ ////toplevel
1365 rotate([0,180,0]) intersection(){
1367 TestSelectTopApertures();
1371 module TestFrameLidPrint(){ ////toplevel
1372 rotate([0,180,0]) intersection(){
1374 TestSelectLidFrame();
1378 module ButtonPlanForDemo(z, deep, cut){
1380 ButtonPlan(8, deep, cut);
1383 module HingeScrews(){
1384 Flip_rhs() Flip_bot(1){
1385 for (c= [ hppT, hppB ])
1390 translate([0,0,-.2])
1391 cylinder( r= hingescrew_shaft_dia/2,
1392 h = hingescrew_shaft_len+0.2 );
1394 translate([0,0,+.1])
1395 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1400 module DemoPropAngleSelect(c){
1401 color(c) difference(){
1402 union(){ children(); }
1403 translate([ prop_x_pos, -400, -200 ])
1404 cube([ 400,800,400 ]);
1408 module DemoPropAngle(ang){
1409 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1410 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1418 DemoPropAngleSelect("red") Case();
1421 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1422 PropProfileAssignments(ang) {
1424 rotate([-$prp_theta, 0, 0])
1425 translate([0, $prpp1[0], -$prpp1[1]])
1431 translate([0,0, -hp_k*2])
1432 DemoPropAngleSelect("blue")
1436 module DemoPropAngles(){ ////toplevel
1437 for (i=[0 : len(prop_angles)-1])
1438 translate(i * [0, -100, 100])
1439 DemoPropAngle(prop_angles[i]);
1442 module DemoHingeAngle(ang1,ang2){
1443 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1444 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1455 color("blue") intersection(){
1458 translate([bppJ[0], -400, -200])
1460 cube([400, 800, 400]);
1461 translate([10, -400, -200])
1462 cube([10, 800, 400]);
1467 module DemoHingeAngles(){ ////toplevel
1468 angles = [ 0, 4, 8, 12 ];
1469 echo("angles",angles);
1470 for (i=[0 : len(angles)-1]) {
1471 translate(i * [0, 0, 30]) {
1472 DemoHingeAngle(0,angles[i]);
1473 translate([0, 200, 0])
1474 DemoHingeAngle(angles[i],0);
1479 module DemoSelectAdhocLeftRight(right=0) {
1480 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1481 mirror([1-right, 0,0])
1482 cube([400, 800, 200]);
1485 module DemoLeft(){ ////toplevel
1486 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1487 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1490 module DemoFrame(){ ////toplevel
1491 color("red") TestFrameCase();
1492 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1493 color("black") HingeScrews();
1497 module DemoHingedFrame(){ ///toplevel
1498 color("red") TestFrameCase();
1499 translate([0,0, -2*hp_k])
1500 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1503 color("orange") HingeLever();
1504 color("black") HingeScrews();
1508 module DemoHinge(){ ////toplevel
1509 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1511 translate([0,0, -hp_k*3])
1516 module DemoProfiles(){ ////toplevel
1520 translate([0,0,-1]) color("black") KeeperProfile(1);
1526 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1528 color("blue") ButtonCoverProfile();
1530 rectfromto(bppQ, demopoint_QR);
1531 rectfromto(bppR, demopoint_QR);
1535 translate([-20,0]) {
1536 color("black") ButtonPlanForDemo(-2, 0,1);
1537 color("red" ) ButtonPlanForDemo(-4, 1,1);
1538 color("blue") ButtonPlanForDemo(-6, 1,0);
1541 translate([0, -30]) {
1544 color("blue") HingeLidProfile();
1545 color("red") HingeBaseProfile();
1546 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1550 translate([-30, -60 + 30*f]) {
1551 translate([0,0,-4]) EdgeProfile();
1552 %translate([0,0,-10]) HingeBaseProfile();
1553 translate([0,-2] * f * hp_k) {
1554 translate([0,0,-4]) LidEdgeProfile();
1555 %translate([0,0,-10]) %HingeLidProfile();
1557 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1558 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1559 translate([0,0,0]) color("red") difference(){
1560 HingeLeverOuterProfile();
1561 HingeLeverInnerProfile();
1563 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1568 translate([20,-30]) {
1571 //translate([0,0,1]) CatchCutProfile();
1572 color("blue") CatchCatchProfile();
1573 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
1576 translate([40,-30]) {
1580 PropProfile(10, 1, 0);
1585 translate([60,-30]) {
1586 PropAggregateProfile();