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