fairphone-case.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 phone = [ 75.0, 145.0 ];
   6
   7 prop_x_pos = 18;
   8
   9 prop_angles = [ 15, 30, 45, 60 ];
  10
  11 bumper = [ 0.250, -0.025 ];
  12 // ^ One side.  Overall size is increased by twice this.
  13 // If no bumpers, is the gap around the phone.
  14
  15 enable_support = 1;
  16
  17 phone_cnr_rad = 6.0;
  18
  19 button_cutout_depth = 9;
  20
  21 phone_edge_thick = 9.0;
  22 phone_total_thick = 12.0;
  23 phone_backside_slope_inner = 1.5; // larger means shallower
  24 phone_backside_slope_outer = 1.0; // larger means shallower
  25
  26 camera_pos_tl = [  6.450, 12.750 ]; // measured from tl corner
  27 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
  28
  29 jack_pos = [ 14.38, 7.96 ];
  30 jack_dia = 10.64 + .5; // some jack I had lying around
  31
  32 noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
  33 noisecancelmic_dia = 4.00;
  34
  35 //fingerpushhole_dias = [ 15, 18 ];
  36 fingerpushhole_dias = [];
  37
  38 rearspeaker_pos_bl = [ 12.64, 18.72 ];
  39 rearspeaker_size   = [  3.76,  7.36 ];
  40
  41 microusb_above = 3.27 - 0.25;
  42 microusb_below = 0.0;
  43 microusb_width = 16.12 + 1.25;
  44
  45 case_th_bottom = 2.5;
  46 case_th_lid = 2.5;
  47 case_th_side = 2;
  48 case_th_lip = 1.2;
  49
  50 case_struts_count = 6;
  51 case_struts_solid_below = 1.00;
  52 case_struts_solid_above = 0.75;
  53 case_struts_width = 0.10;
  54
  55 keeper_th_z = 0.75;
  56 keeper_th_x = 0.75;
  57 keeper_inner_width = 2.75;
  58 keeper_inner_height = 2.75;
  59 keeper_slant_slope = 2; // larger means steeper
  60
  61 keeper_gap_z_top = 0.25;
  62 keeper_gap_z_bot = 0.75;
  63 keeper_gap_x     = 0.25;
  64 keeper_gap_x_holes = 0.75;
  65
  66 keeper_side = 0; // 0 = lhs; 1 = rhs
  67
  68 case_lip = 1.25;
  69
  70 lid_gap_x = 0.25;
  71 lid_gap_z = 0.25;
  72 lid_lip = 1.75;
  73
  74 catch_slop = 0.50;
  75
  76 foldover_gap = 0.50;
  77 foldover_lever_gap = 0.50;
  78
  79 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
  80 hingescrew_shaft_len = 12;
  81 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
  82 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
  83 hingescrew_head_th = 1.38 + 0.75;
  84 hingescrew_head_dia = 3.92;
  85 lever_cover_th = 0.75;
  86 hingemount_th = 2.5;
  87
  88 $fa = 5;
  89 $fs = 0.1;
  90
  91 button_l_fudge = 4.4;
  92 buttonishleg_default_l_is_fudge = 10;
  93
  94 hinge_base_slope = 1.5; // bigger is steeper
  95
  96 strut_min_at_end = 1.5;
  97
  98 hinge_x_gap = 0.125;
  99 hinge_x_postscrew_gap = 0.75;
 100 hinge_x_arms_gap = 0.35;
 101 hinge_r_arms_gap = 0.55;
 102
 103 rearspeaker_gap    = [ 2.0, 2.0 ]; // each side
 104
 105 catch_len = 7.5;
 106 catch_width = 15;
 107 catch_thickness = 1.0;
 108 catch_side_gap = 0.75; // each side
 109
 110 catch_depth = 0.75;
 111 catch_height = 0.35;
 112 catch_finger_height = 1.5;
 113 catch_finger_depth = 2.5;
 114
 115 prop_recess_under = 0.50;
 116 prop_recess_slop = 0.200; // each side
 117 prop_end_dia = 0.5;
 118 prop_main_th = 3;
 119 prop_taper_len = 6;
 120 prop_main_width = 3;
 121 prop_side_gap = 0.75; // each side
 122 prop_caserecess_behind = 0.75;
 123 prop_caserecess_taper = 0.25; // each side
 124
 125 // ---------- calculated ----------
 126
 127 phone_width =  (phone + bumper*2)[0];
 128 phone_height = (phone + bumper*2)[1];
 129
 130 inside_br = [phone_width, -phone_height];
 131
 132 //echo(camera_pos_tl + bumper,
 133 //     camera_pos_br + bumper);
 134
 135 // ----- could be changed -----
 136 lid_buttoncover_gap = lid_gap_x;
 137 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
 138
 139 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
 140
 141 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
 142
 143 //prop_nose_len = case_th_lid - prop_recess_under;
 144 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
 145 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
 146
 147
 148 //lid_lip_overlap_width xxx bad name = ;
 149 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
 150
 151 epp0 = [0,0];
 152 epp1 = [0, -phone_edge_thick];
 153 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
 154 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
 155 epp3 = epp2i + [10, 0];
 156 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
 157 epp4 = epp5 + [-1,0] * case_th_side;
 158
 159 kppe = [0,0];
 160 kppd = kppe + [1,0] * keeper_inner_width;
 161 kppc = kppd + [0,1] * keeper_th_z;
 162 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
 163 kppf = kppe - [0,1] * keeper_inner_height;
 164 kppa = [ kppb[0], kppf[1] ];
 165
 166 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
 167 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 168
 169 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
 170
 171 lpp12 = [ epp4[0] + lp_r12,    lpp11[1] ];
 172 lpp13 = [ lpp12[0],            lpp12[1] + lp_r12 ];
 173
 174 case_bottom_z = epp2o[1] - case_th_bottom;
 175
 176 // button profile
 177 bppM = epp4 + [0,5];
 178 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
 179 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
 180 bppS = [ epp1[0], bppR[1] ];
 181 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
 182 bppP = bppQ + [0,1] * lid_buttoncover_gap;
 183 bppO = [ bppN[0], bppP[1] ];
 184 bppL = lpp10 + [5,0];
 185 bppK = [ bppL[0], bppN[1] ];
 186 bppJ = [ bppN[0], bppL[1] ];
 187
 188 // hinge plan
 189 hp_rn = hingescrew_nut_dia/2;
 190 hp_r2_min = hp_rn + lever_cover_th;
 191 hp_rs = hingescrew_shaft_dia/2;
 192 hp_r1_min = hp_rs + hingemount_th;
 193
 194 hp_r1 = max(hp_r1_min, hp_r2_min);
 195 hp_r2 = hp_r1;
 196
 197 hppU = lpp13;
 198 hppS = epp2o + [0,-1] * case_th_bottom;
 199 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
 200
 201 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
 202          0.5 * (hppU + hppS)[1] ];
 203 hppT = [ hppM[0], hppU[1] - hp_r1 ];
 204 hppB = hppT + [0,-1] * hp_k;
 205
 206 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
 207 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
 208 hppE = [ hppE_x, hppE_y ];
 209
 210 // hinge elevation x coords
 211
 212 hingescrew_portion_len =
 213   0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
 214
 215 hex20 = max(epp2o[0],
 216             phone_cnr_rad,
 217             kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
 218 hex21 = hex20 + hingescrew_portion_len;
 219 hex22 = hex21 + hinge_x_gap;
 220 hex23 = hex22 + hingescrew_portion_len
 221   - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
 222 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
 223 //echo(hex20, hex21, hex22, hex23, hex24);
 224 //echo(hingescrew_portion_len);
 225
 226 // catch
 227
 228 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
 229 cppA = cppJ + [lid_gap_x, -lid_gap_z];
 230 cppB = [ epp0[0], cppA[1] ];
 231 cppP = [ epp4[0], cppJ[1] ];
 232
 233 cppS = cppJ + [0,-1] * catch_len;
 234 cppD = [ cppA[0], cppS[1] + catch_slop ];
 235 cppC = [ cppB[0], cppD[1] ];
 236 cppT = cppS + [1,0] * catch_depth;
 237 cppU = cppT + [0,-1] * catch_height;
 238 cppV = [ cppS[0], cppU[1] - catch_depth ];
 239
 240 cppR = 0.5*(cppP + cppJ);
 241
 242 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
 243 cppQ = [ cppR[0],
 244          cppV[1] - (catch_finger_height - cp_rQ) ];
 245 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
 246
 247 // prop recess
 248
 249 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
 250
 251 prcp2 = [ epp4[0], case_bottom_z ];
 252
 253 prop_caserecess_buildout_r = prcp2[0] - epp2o[0];
 254
 255 prc_r1 = prop_end_dia/2;
 256 prc_r3 = prc_r1 + prop_recess_slop;
 257 echo(prc_r3);
 258
 259 prcp1 = [ prcp2[0] + prop_caserecess_behind + prc_r3,
 260           epp2i[1] - prc_r3 ];
 261
 262 // ---------- modules ----------
 263
 264 module KeeperProfile(slant=0){
 265   use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
 266   polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
 267 }
 268
 269 module EdgeProfile(){
 270   difference(){
 271     hull(){
 272       translate(epp3) square(case_th_bottom*2, center=true);
 273       circleat(epp2o, r=case_th_bottom);
 274       circleat(epp1, r=case_th_side);
 275       rectfromto(epp0, epp4);
 276     }
 277     polygon([ epp5 + [0,10],
 278               epp1,
 279               epp2i,
 280               epp3 + [10,0] ]);
 281   }
 282 }
 283
 284 module LidEdgeProfile(){
 285   polygon([ lpp10,
 286             lpp11,
 287             lpp12,
 288             lpp13,
 289             lpp13 + [10, 0],
 290             lpp10 + [10, 0]
 291             ]);
 292   intersection(){
 293     circleat(lpp12, r=lp_r12);
 294     rectfromto( lpp12 + [-10,   0],
 295                 lpp12 + [+10, +10] );
 296   }
 297 }
 298
 299 module ButtonCoverProfile(){
 300   intersection(){
 301     polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
 302     hull(){
 303       EdgeProfile();
 304       LidEdgeProfile();
 305     }
 306   }
 307 }
 308
 309 module ButtonPlan(l, deep, cut){
 310   epsilon =
 311     (cut  ? 0 : lid_buttoncover_gap);
 312
 313   delta =
 314     (deep ? lid_buttoncover_overlap : 0);
 315
 316   C = [0,0]; // by definition
 317   T = [ 0, epp4[1] ];
 318   G = T + [0,10];
 319
 320   B0 = C + [0,-1] * button_cutout_depth;
 321   B1 = B0 + [0,1] * epsilon;
 322
 323   r0 = 0.5 * (T[1] - B0[1]);
 324   A = [  -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
 325   H = A + [0,-1] * delta;
 326
 327   D = A + [-2,0] * r0;
 328   F = D + [0,10];
 329
 330   E0 = 0.5 * (D + A);
 331   E1 = E0 + [1,0] * epsilon;
 332
 333   I0 = [ E0[0], H[1] ];
 334   I1 = [ E1[0], H[1] ];
 335
 336   hull(){
 337     for (m=[0,1]) mirror([m,0])
 338       circleat(H, r0 - epsilon);
 339   }
 340   for (m=[0,1]) mirror([m,0]) {
 341     difference(){
 342       polygon([ E1,
 343                 I1,
 344                 H,
 345                 B1,
 346                 G,
 347                 F,
 348                 D
 349                 ]);
 350       circleat(D, r0 + epsilon);
 351     }
 352   }
 353 }
 354
 355 module CatchCatchProfile(){
 356   hull(){
 357     for (c=[ cppR, cppQ ])
 358       circleat(c, cp_rQ);
 359   }
 360   hull(){
 361     circleat(lpp12, lp_r12);
 362     circleat(lpp12 + [5,0], lp_r12);
 363     rectfromto(cppP, cppP + [5,0.1]);
 364   }
 365   polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
 366 }
 367
 368 module CatchCutProfile(){
 369   polygon([ cppB,
 370             cppA,
 371             cppD,
 372             cppF,
 373             cppF + [0,-10],
 374             cppF + [-10,-10],
 375             lpp12 + [-10,0],
 376             lpp12 + [10,0]
 377             ]);
 378 }
 379
 380 module Flip_rhs(yn=[0,1]) {
 381   for ($rhsflip=yn) {
 382     translate([phone_width/2, 0, 0])
 383       mirror([$rhsflip,0,0])
 384       translate([-phone_width/2, 0, 0])
 385       children();
 386   }
 387 }
 388
 389 module Flip_bot(yn=[0,1]) {
 390   for ($botflip=yn) {
 391     translate([0, -phone_height/2, 0])
 392       mirror([0, $botflip, 0])
 393       translate([0, phone_height/2, 0])
 394       children();
 395   }
 396 }
 397
 398 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
 399   // sides
 400   Flip_rhs(){
 401     translate([0, -phone_cnr_rad, 0])
 402       rotate([90,0,0])
 403       linear_extrude(height = phone_height - phone_cnr_rad*2)
 404       children(0);
 405   }
 406   // corners
 407   Flip_rhs() Flip_bot() {
 408     translate([+1,-1] * phone_cnr_rad)
 409       intersection(){
 410         rotate_extrude()
 411           intersection(){
 412             mirror([1,0,0])
 413               translate([-1,0] * phone_cnr_rad)
 414               children(0);
 415             rectfromto([0,-20],[10,20]);
 416           }
 417         translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
 418           cube([10,10,40]);
 419       }
 420   }
 421   // top and bottom
 422   Flip_bot(){
 423     translate([ phone_width - phone_cnr_rad, 0,0 ])
 424       rotate([90,0,-90])
 425       linear_extrude(height = phone_width - phone_cnr_rad*2)
 426       children(0);
 427   }
 428   // fill
 429   translate([0,0, fill_zstart])
 430     mirror([0,0, fill_downwards])
 431     linear_extrude(height = fill_th)
 432     rectfromto([+1,-1] * phone_cnr_rad,
 433                [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 434 }
 435
 436 module CaseAperture(pos, dia, $fn) {
 437   theta = 180/$fn;
 438   translate([ pos[0] + bumper[0],
 439               -epp2i[0],
 440               -pos[1] ])
 441     rotate([-90, theta, 0])
 442     cylinder(r = dia/2 / cos(theta),
 443              h = 60);
 444 }
 445
 446 module SideButton(y, y_ref_sign, l){
 447   // y_ref_sign:
 448   //   +1  measured from top    of actual phone to top    of button
 449   //   -1  measured from bottom of actual phone to bottom of button
 450   //    0  y is centre of button in coordinate system
 451   $button_l= l;
 452   eff_y = y_ref_sign > 0 ?         -bumper [1] -y -l/2 :
 453           y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
 454           y;
 455   //echo(eff_y);
 456   translate([0, eff_y, 0])
 457     children();
 458 }
 459
 460 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 461   $button_leg_only = true;
 462   SideButton(y, y_ref_sign, l) children();
 463 }
 464
 465 module Buttons(){
 466   Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
 467   Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
 468   Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
 469   Flip_rhs(   ) LidButtonishLeg(14, -1) children();
 470 //  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 471 }
 472
 473 module Struts(x_start, z_min, th){
 474   // if th is negative, starts at z_min and works towards -ve z
 475   // and object should then be printed other way up
 476   for (i= [1 : 1 : case_struts_count]) {
 477     translate([0,
 478                0,
 479                z_min])
 480       mirror([0,0, th<0 ? 1 : 0])
 481       translate([0,
 482                  -phone_height * i / (case_struts_count+1),
 483                  case_struts_solid_below])
 484       linear_extrude(height= abs(th)
 485                      -(case_struts_solid_below+case_struts_solid_above))
 486       rectfromto([               x_start, -0.5 * case_struts_width ],
 487                  [ phone_width - x_start, +0.5 * case_struts_width ]);
 488   }
 489 }
 490
 491 module OrdinaryRearAperture(rhs,bot, pos){
 492   Flip_rhs(rhs) Flip_bot(bot)
 493     linextr(-20, 20)
 494     mirror([0,1])
 495     translate(pos + bumper)
 496     children();
 497 }
 498
 499 module MicroUSB(){
 500   Flip_bot(1){
 501     rotate([90,0,0])
 502       mirror([0,0,1])
 503       linextr(-epp2i[0], 60)
 504       translate([0.5 * phone_width, 0, 0])
 505       rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
 506                  [+microusb_width/2, epp0[1] + -microusb_above]);
 507   }
 508 }
 509
 510 module OrdinaryRearApertures(){
 511   // rear speaker
 512   OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
 513     rectfromto(-rearspeaker_gap,
 514                rearspeaker_size + rearspeaker_gap);
 515
 516   // finger hole to remove phone
 517   if (len(fingerpushhole_dias))
 518     OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
 519                                 phone[1]/2 ])
 520     scale(fingerpushhole_dias)
 521     circle(r= 0.5 );
 522 }
 523
 524 module RearCameraAperture(){
 525   Flip_rhs(1)
 526     mirror([0, 0, 1])
 527     linear_extrude(height = 20)
 528     mirror([0, 1, 0])
 529     translate(bumper)
 530     rectfromto(camera_pos_tl, camera_pos_br);
 531 }
 532
 533 module HingeLidProfile(){
 534   hull(){
 535     circleat(hppT, hp_r1);
 536     circleat(lpp12, lp_r12);
 537     polygon([lpp10,
 538              lpp13 + [2,0],
 539              lpp12,
 540              hppT]);
 541   }
 542 }
 543
 544 module HingeBaseProfile(){
 545   difference(){
 546     hull(){
 547       circleat(hppB, hp_r1);
 548       circleat(hppE, hp_r1);
 549       circleat(epp2o, case_th_bottom);
 550       circleat(hppB + [10,0], hp_r1);
 551     }
 552     polygon([epp5, epp1, epp2i, epp3, bppL]);
 553   }
 554 }
 555
 556 module HingeLeverOuterProfile(){
 557   hull(){
 558     circleat(hppT, hp_r2);
 559     circleat(hppB, hp_r2);
 560   }
 561 }
 562
 563 module HingeLeverInnerProfile(){
 564   for (c = [hppT, hppB]) {
 565     hull()
 566       for (x=[-20,20])
 567         for (y=[0, c[1] - hppM[1]])
 568           translate([x,y])
 569             circleat(c, hp_rn);
 570   }
 571 }
 572
 573 module Flip_hinge(){
 574   hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
 575   translate(hinge_origin)
 576     rotate([180,0,0])
 577     translate(-hinge_origin)
 578     children();
 579 }
 580
 581 module HingePortion(x0,x1){
 582   Flip_rhs() Flip_bot(1)
 583     translate([x0,0,0])
 584     mirror([1,0,0])
 585     rotate([90,0,-90])
 586     linear_extrude(height=x1-x0)
 587     children(0);
 588 }
 589
 590 module CatchPortion(width){
 591   translate([phone_width/2, 0,0])
 592     rotate([90,0,-90])
 593     linextr(-width/2, width/2)
 594     children(0);
 595 }
 596
 597 module CaseBase(){
 598   AroundEdges(epp3[1], case_th_bottom, 1)
 599     EdgeProfile();
 600 }
 601
 602 module Case(){ ////toplevel
 603   difference(){
 604     union(){
 605       CaseBase();
 606
 607       // ledge (fixed keeper)
 608       Flip_rhs(1-keeper_side) intersection(){
 609         rotate([90, 0, 0])
 610           linear_extrude(height = phone_height + phone_cnr_rad * 2)
 611           KeeperProfile(1);
 612
 613         // outline of the whole case, to stop it protruding
 614         translate([0,0, -25])
 615           linear_extrude(height = 50)
 616           hull()
 617           Flip_bot()
 618           circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
 619       }
 620
 621       // hinge
 622       HingePortion(hex20, hex21) HingeBaseProfile();
 623
 624       // buildout for prop recess
 625       Flip_rhs(1)
 626         linextr(case_bottom_z, epp2i[1])
 627         hull() {
 628           for (dxs = [-1,+1])
 629             circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
 630                        -epp2o[0] ],
 631                      r = epp2o[0] - prcp2[0]);
 632         }
 633     }
 634
 635     // slot for keeper
 636     Flip_rhs(keeper_side)
 637       translate([0, -phone_cnr_rad, 0])
 638       rotate([90, 0, 0])
 639       linear_extrude(height = phone_height + phone_cnr_rad * 2)
 640       minkowski(){
 641         KeeperProfile();
 642         rectfromto([ -keeper_gap_x,    -keeper_gap_z_bot ],
 643                    [ keeper_gap_x_holes,    +keeper_gap_z_top ]);
 644       }
 645
 646     // front camera
 647     RearCameraAperture();
 648
 649     // struts (invisible, because they're buried in the case)
 650     Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
 651
 652     Buttons(){
 653       mirror([1,0,0])
 654         rotate([90,0,90]) {
 655           if (!($button_leg_only && enable_support))
 656           intersection(){
 657             translate([0,0,-10])
 658               linear_extrude(height= 20)
 659               ButtonPlan($button_l, 0,1);
 660             if ($button_leg_only)
 661               rotate([-90,90,0])
 662                 translate([phone_width/2, -400, kppe[1]])
 663                 mirror([1-abs($rhsflip - keeper_side),0,0])
 664                 cube([400, 800, 50]);
 665             if (enable_support)
 666               rotate([-90,90,0])
 667               translate([-400, -400, kppd[1]])
 668                 mirror([0,0,1])
 669                 cube([800,800,100]);
 670           }
 671           translate([0,0, -bppR[0]])
 672             linear_extrude(height= 20)
 673             ButtonPlan($button_l, 1,1);
 674         }
 675
 676     }
 677
 678     // apertures along top edge
 679     CaseAperture(jack_pos, jack_dia, 8);
 680     Flip_rhs(1)
 681       CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
 682
 683     OrdinaryRearApertures();
 684
 685     MicroUSB();
 686
 687     // gaps for the lid's hinge arms
 688     HingePortion(hex20 - hinge_x_arms_gap,
 689                  hex21 + hinge_x_arms_gap)
 690       minkowski(){
 691         HingeLidProfile();
 692         circle(r= hinge_r_arms_gap, $fn= 8);
 693       }
 694
 695     // screw holes in the hinge arms
 696     HingeScrews();
 697
 698     // catch striker
 699     CatchPortion(catch_width + catch_side_gap*2)
 700       CatchCutProfile();
 701
 702     // prop recess
 703     Flip_rhs(1)
 704       translate([0,0,1])
 705       rotate([90,0,90])
 706       linextr(-prop_recess_hw, +prop_recess_hw)
 707       hull(){
 708         for (zs=[ -1,0,+1 ])
 709           circleat(prcp2 + 20*(abs(zs) * [0,-1] +
 710                                zs * [1,0] * prop_caserecess_taper),
 711                    prc_r3);
 712       }
 713   }
 714 }
 715
 716 module Lid(){ ////toplevel
 717   difference(){
 718     union(){
 719       AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
 720         LidEdgeProfile();
 721
 722       // button covers
 723       Buttons(){
 724         intersection(){
 725           rotate([90,0,90])
 726             translate([0,0,-10])
 727             linear_extrude(height= 20)
 728             ButtonPlan($button_l, 1,0);
 729           rotate([90,0,0])
 730              translate([0,0,-100])
 731             linear_extrude(height= 200)
 732             ButtonCoverProfile();
 733         }
 734       }
 735
 736       // hinge arms
 737       HingePortion(hex20, hex21) HingeLidProfile();
 738
 739       // catch
 740       CatchPortion(catch_width)
 741         CatchCatchProfile();
 742     }
 743     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
 744
 745     // screw holes in the hinge arms
 746     HingeScrews();
 747   }
 748 }
 749
 750 module HingeLever(){ ////toplevel
 751   difference() {
 752     // outer body, positive
 753     HingePortion(hex22, hex22 + phone_width/2)
 754       HingeLeverOuterProfile();
 755
 756     // space for the screws
 757     HingePortion(hex23, hex24)
 758       HingeLeverInnerProfile();
 759
 760     // bores for the screws
 761     HingeScrews();
 762
 763     // space for the charging cable
 764     MicroUSB();
 765     Flip_hinge() MicroUSB();
 766   }
 767 }
 768
 769 module HingeLeverPrint(){ ////toplevel
 770   rotate([90,0,0])
 771     HingeLever();
 772 }
 773
 774 module TestSelectLength(){
 775   translate([-30, -200, -20])
 776     cube([30 + 15, 250, 40]);
 777 }
 778
 779 module TestLength(){ ////toplevel
 780   intersection(){
 781     Case();
 782     TestSelectLength();
 783   }
 784 }
 785
 786 module TestLengthRight(){ ////toplevel
 787   intersection(){
 788     Case();
 789     Flip_rhs(1)
 790       TestSelectLength();
 791   }
 792 }
 793
 794 module TestSelectWidth(){
 795   translate([-30, -(phone_height - 25), -20])
 796     mirror([0, 1, 0])
 797     cube([200, 50, 40]);
 798 }
 799
 800 module TestWidth(){ ////toplevel
 801   intersection(){
 802     Case();
 803     TestSelectWidth();
 804   }
 805 }
 806
 807 module TestLidWidthPrint(){ ////toplevel
 808   rotate([0,180.0]) intersection(){
 809     Lid();
 810     TestSelectWidth();
 811   }
 812 }
 813
 814 module TestSelectRearAperture(){
 815   minkowski(){
 816     union() children();
 817     translate([20, 0,0])
 818       cube([42, 2, 1], center=true);
 819   }
 820 }
 821
 822 module TestSelectCamera(){
 823   minkowski(){
 824     TestSelectRearAperture()
 825       RearCameraAperture();
 826     cube([0.1, 50, 0.1]);
 827   }
 828 }
 829
 830 module TestSelectOrdinaryRearApertures(){
 831   TestSelectRearAperture()
 832     OrdinaryRearApertures();
 833 }
 834
 835 module TestCamera(){ ////toplevel
 836   intersection(){
 837     Case();
 838     TestSelectCamera();
 839   }
 840 }
 841
 842 module TestLidByCamera(){ ////toplevel
 843   intersection(){
 844     Lid();
 845     TestSelectCamera();
 846   }
 847 }
 848
 849 module TestLidByCameraPrint(){ ////toplevel
 850   rotate([180,0,0]) TestLidByCamera();
 851 }
 852
 853 module DemoByCamera(){ ////toplevel
 854   color("blue") TestLidByCamera();
 855   color("red")  TestCamera();
 856 }
 857
 858 module OneKeeper(){ ////toplevel
 859   translate([0, -phone_cnr_rad, 0])
 860     rotate([90, 0, 0])
 861     linear_extrude(height = phone_height - phone_cnr_rad * 2)
 862     KeeperProfile();
 863 }
 864
 865 module OneKeeperPrint(){ ////toplevel
 866   rotate([0,180,0])
 867     OneKeeper();
 868 }
 869
 870 module LidPrint(){ ////toplevel
 871   rotate([0,180,0])
 872     Lid();
 873 }
 874
 875 module TestSelectPropRecesses(posns){
 876   linextr(-100,100){
 877     translate([phone_width/2, -phone_height]){
 878       square([ 3, 500 ], center=true);
 879       for (y=posns)
 880         hull()
 881           for (dy=[ -prp5[0], -prp2[0] ])
 882             translate([0,y+dy])
 883               square([prop_main_width+5, 5], center=true);
 884     }
 885   }
 886 }
 887
 888 module TestSelectFrame(){
 889   include = [1,-1] * (epp2i[0] + 4);
 890
 891   difference(){
 892     cube(1000, center=true);
 893     translate([0,0, -100])
 894       linear_extrude(height=200)
 895       rectfromto(include,  inside_br - include);
 896   }
 897 }
 898
 899 module TestSelectLidFrame(){
 900   TestSelectFrame();
 901   TestSelectPropRecesses(prop_lid_posns);
 902 }
 903
 904 module TestFrameCase(){ ////toplevel
 905   intersection(){
 906     Case();
 907     union(){
 908       TestSelectFrame();
 909       TestSelectCamera();
 910       TestSelectOrdinaryRearApertures();
 911     }
 912   }
 913 }
 914
 915 module TestFrameLidPrint(){ ////toplevel
 916   rotate([0,180,0]) intersection(){
 917     Lid();
 918     TestSelectLidFrame();
 919   }
 920 }
 921
 922 module ButtonPlanForDemo(z, deep, cut){
 923   translate([0,0,z])
 924     ButtonPlan(8, deep, cut);
 925 }
 926
 927 module HingeScrews(){
 928   Flip_rhs() Flip_bot(1){
 929     for (c= [ hppT, hppB ])
 930       translate([ hex20,
 931                   -c[0],
 932                   c[1] ]){
 933         rotate([0,90,0])
 934           translate([0,0,-.2])
 935           cylinder( r= hingescrew_shaft_dia/2,
 936                     h = hingescrew_shaft_len+0.2 );
 937         rotate([0,-90,0])
 938           translate([0,0,+.1])
 939           cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
 940       }
 941   }
 942 }
 943
 944 module DemoFrame(){ ////toplevel
 945   color("red") TestFrameCase();
 946   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
 947   color("black") HingeScrews();
 948   %HingeLever();
 949 }
 950
 951 module DemoHingedFrame(){ ///toplevel
 952   color("red") TestFrameCase();
 953   translate([0,0, -2*hp_k])
 954   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
 955
 956   Flip_hinge(){
 957     color("orange") HingeLever();
 958     color("black") HingeScrews();
 959   }
 960 }
 961
 962 module DemoHinge(){ ////toplevel
 963   DemoFrame();
 964   translate([0,0, -hp_k*3])
 965     DemoHingedFrame();
 966 }
 967
 968 module DemoProfiles(){ ////toplevel
 969   LidEdgeProfile();
 970   %EdgeProfile();
 971   KeeperProfile();
 972   translate([0,0,-1]) color("black") KeeperProfile(1);
 973
 974   translate([20,0]) {
 975     LidEdgeProfile();
 976     %EdgeProfile();
 977
 978     demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
 979
 980     color("blue") ButtonCoverProfile();
 981     color("red") {
 982       rectfromto(bppQ, demopoint_QR);
 983       rectfromto(bppR, demopoint_QR);
 984     }
 985   }
 986
 987   translate([-20,0]) {
 988     color("black") ButtonPlanForDemo(-2, 0,1);
 989     color("red" )  ButtonPlanForDemo(-4, 1,1);
 990     color("blue")  ButtonPlanForDemo(-6, 1,0);
 991   }
 992
 993   translate([0, -30]) {
 994     %LidEdgeProfile();
 995     %EdgeProfile();
 996     color("blue") HingeLidProfile();
 997     color("red")  HingeBaseProfile();
 998     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
 999     color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
1000   }
1001
1002   translate([20,-30]) {
1003     %EdgeProfile();
1004     %LidEdgeProfile();
1005     //translate([0,0,1]) CatchCutProfile();
1006     color("blue") CatchCatchProfile();
1007     color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
1008   }
1009 }
1010
1011 //EdgeProfile();
1012 //KeeperProfile();
1013 //CaseBase();
1014 //%Case();
1015 //Keeper();
1016 //LidEdgeProfile();
1017 //KeeperProfile();
1018 //DemoProfiles();
1019 //PropRecess();