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 // button profile
  79 bppM = epp4 + [0,5];
  80 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
  81 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
  82 bppS = [ epp1[0], bppR[1] ];
  83 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
  84 bppP = bppQ + [0,1] * lid_buttoncover_gap;
  85 bppO = [ bppN[0], bppP[1] ];
  86 bppL = lpp10 + [5,0];
  87 bppK = [ bppL[0], bppN[1] ];
  88 bppJ = [ bppN[0], bppL[1] ];
  89
  90 module rectfromto(a,b) {
  91   ab = b - a;
  92   translate([min(a[0], b[0]), min(a[1], b[1])])
  93     square([abs(ab[0]), abs(ab[1])]);
  94 }
  95 module circleat(c,r) { translate(c) circle(r); }
  96
  97 module KeeperProfile(){
  98   polygon([kppe, kppd, kppc, kppb, kppa, kppf]);
  99 }
 100
 101 module EdgeProfile(){
 102   difference(){
 103     hull(){
 104       translate(epp3) square(case_th_bottom*2, center=true);
 105       circleat(epp2o, r=case_th_bottom);
 106       circleat(epp1, r=case_th_side);
 107       rectfromto(epp0, epp4);
 108     }
 109     polygon([ epp5 + [0,10],
 110               epp1,
 111               epp2i,
 112               epp3 + [10,0] ]);
 113   }
 114 }
 115
 116 module LidEdgeProfile(){
 117   polygon([ lpp10,
 118             lpp11,
 119             lpp12,
 120             lpp13,
 121             lpp13 + [10, 0],
 122             lpp10 + [10, 0]
 123             ]);
 124   intersection(){
 125     circleat(lpp12, r=lid_lip);
 126     rectfromto( lpp12 + [-10,   0],
 127                 lpp12 + [+10, +10] );
 128   }
 129 }
 130
 131 module ButtonCoverProfile(){
 132   intersection(){
 133     polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
 134     hull(){
 135       EdgeProfile();
 136       LidEdgeProfile();
 137     }
 138   }
 139 }
 140
 141 module ButtonPlan(l, bigger, d_D1_y){
 142   C = [0,0]; // by definition
 143   T = [ 0, epp4[1] ];
 144   G = T + [0,10];
 145   B0 = T + [0,-1] * button_cutout_depth;
 146   r0 = 0.5 * (T[1] - B0[1]);
 147   A = [  -l/2 + r0, 0.5 * (T[1] + B0[1]) ];
 148   r1 = r0 + bigger;
 149   // | D1 - A | = r1 * 2
 150   // D1_y = T_y - r1 + d_D1_y
 151   // =>    4 * r1^2   =  (r1-r0 + d_D1_y)^2 + (D1_x - A_x)^2
 152   // =>    D1_x =  A_x + v/~ [  4 * r1^2   -   (r1-r0 + d_D1_y)^2 ]
 153   D1  = [ A[0] + sqrt( 4*r1*r1 - pow(bigger + d_D1_y, 2) ),
 154           T[1] - r1 + d_D1_y ];
 155   E1  = 0.5 * (D1 + A);
 156   F1  = D1 + [0,10];
 157
 158   hull(){
 159     for (m=[0,1]) mirror([m,0])
 160       circleat(A, r1);
 161   }
 162   for (m=[0,1]) mirror([m,0]) {
 163     difference(){
 164       polygon([ E1,
 165                 A,
 166                 B0,
 167                 G,
 168                 F1,
 169                 D1
 170                 ]);
 171       circleat(D1, r1);
 172     }
 173   }
 174 }
 175
 176 module CaseBase_rhsflip(yn=[0,1]) {
 177   for (rhs=yn) {
 178     translate([phone_width/2, 0, 0])
 179       mirror([rhs,0,0])
 180       translate([-phone_width/2, 0, 0])
 181       children();
 182   }
 183 }
 184
 185 module CaseBase_botflip() {
 186   for (bot=[0,1]) {
 187     translate([0, -phone_height/2, 0])
 188       mirror([0, bot, 0])
 189       translate([0, phone_height/2, 0])
 190       children();
 191   }
 192 }
 193
 194 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
 195   // sides
 196   CaseBase_rhsflip(){
 197     translate([0, -phone_cnr_rad, 0])
 198       rotate([90,0,0])
 199       linear_extrude(height = phone_height - phone_cnr_rad*2)
 200       children(0);
 201   }
 202   // corners
 203   CaseBase_rhsflip() CaseBase_botflip() {
 204     translate([+1,-1] * phone_cnr_rad)
 205       intersection(){
 206         rotate_extrude()
 207           intersection(){
 208             mirror([1,0,0])
 209               translate([-1,0] * phone_cnr_rad)
 210               children(0);
 211             rectfromto([0,-20],[10,20]);
 212           }
 213         translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
 214           cube([10,10,40]);
 215       }
 216   }
 217   // top and bottom
 218   CaseBase_botflip(){
 219     translate([ phone_width - phone_cnr_rad, 0,0 ])
 220       rotate([90,0,-90])
 221       linear_extrude(height = phone_width - phone_cnr_rad*2)
 222       children(0);
 223   }
 224   // fill
 225   translate([0,0, fill_zstart])
 226     mirror([0,0, fill_downwards])
 227     linear_extrude(height = fill_th)
 228     rectfromto([+1,-1] * phone_cnr_rad,
 229                [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 230 }
 231
 232 module CaseBase(){
 233   AroundEdges(epp3[1], case_th_bottom, 1)
 234     EdgeProfile();
 235 }
 236
 237 module Case(){ ////toplevel
 238   difference(){
 239     union(){
 240       CaseBase();
 241
 242       // ledge (fixed keeper)
 243       intersection(){
 244         rotate([90, 0, 0])
 245           linear_extrude(height = phone_height + phone_cnr_rad * 2)
 246           KeeperProfile();
 247
 248         // outline of the whole case, to stop it protruding
 249         translate([0,0, -25])
 250           linear_extrude(height = 50)
 251           hull()
 252           // CaseBase_rhsflip() // actually, we only care about the LH
 253           CaseBase_botflip()
 254           circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
 255       }
 256     }
 257
 258     // slot for keeper
 259     CaseBase_rhsflip(1)
 260       translate([0, -phone_cnr_rad, 0])
 261       rotate([90, 0, 0])
 262       linear_extrude(height = phone_height + phone_cnr_rad * 2)
 263       minkowski(){
 264         KeeperProfile();
 265         rectfromto([ -keeper_gap_x,    -keeper_gap_z_bot ],
 266                    [ keeper_gap_x_holes,    +keeper_gap_z_top ]);
 267       }
 268
 269     // front camera
 270     CaseBase_rhsflip([1])
 271       mirror([0, 0, 1])
 272       linear_extrude(height = 20)
 273       mirror([0, 1, 0])
 274       rectfromto(camera_pos_tl, camera_pos_br);
 275
 276     // struts (invisible, because they're buried in the case)
 277     for (i= [1 : 1 : case_struts_count]) {
 278       translate([0,
 279                  -phone_height * i / (case_struts_count+1),
 280                  epp2i[1] - case_th_bottom + case_struts_solid_below])
 281         linear_extrude(height= case_th_bottom
 282                        -(case_struts_solid_below+case_struts_solid_above))
 283         rectfromto([               epp2i[0], -0.5 * case_struts_width ],
 284                    [ phone_width - epp2i[0], +0.5 * case_struts_width ]);
 285     }
 286   }
 287 }
 288
 289 module Lid(){ ////toplevel
 290   AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
 291     LidEdgeProfile();
 292 }
 293
 294 module TestLength(){ ////toplevel
 295   intersection(){
 296     Case();
 297     translate([-30, -200, -20])
 298     cube([30 + 15, 250, 40]);
 299   }
 300 }
 301
 302 module TestWidth(){ ////toplevel
 303   intersection(){
 304     Case();
 305     translate([-30, -(phone_height - 25), -20])
 306       mirror([0, 1, 0])
 307       cube([200, 50, 40]);
 308   }
 309 }
 310
 311 module TestLidWidthPrint(){ ////toplevel
 312   rotate([0,180.0])
 313     intersection(){
 314       Lid();
 315       translate([-30, -(phone_height - 25), -20])
 316         mirror([0, 1, 0])
 317         cube([200, 50, 40]);
 318     }
 319 }
 320
 321 module TestCamera(){ ////toplevel
 322   intersection(){
 323     Case();
 324     CaseBase_rhsflip(1)
 325       translate([0,0,-25])
 326       linear_extrude(height = 50)
 327       mirror([0, 1, 0])
 328       rectfromto([-20, -20],
 329                  camera_pos_br + [ 5, 5 ]);
 330   }
 331 }
 332
 333 module OneKeeper(){ ////toplevel
 334   translate([0, -phone_cnr_rad, 0])
 335     rotate([90, 0, 0])
 336     linear_extrude(height = phone_height - phone_cnr_rad * 2)
 337     KeeperProfile();
 338 }
 339
 340 module OneKeeperPrint(){ ////toplevel
 341   rotate([0,180,0])
 342     OneKeeper();
 343 }
 344
 345 module Keeper(){ ////toplevel
 346   CaseBase_rhsflip()
 347     OneKeeper();
 348 }
 349
 350 module ButtonPlanForDemo(colour, z, gap, overlap){
 351   color(colour)
 352     translate([0,0,z])
 353     ButtonPlan(8,
 354                lid_buttoncover_gap * gap +
 355                lid_buttoncover_overlap * overlap,
 356                lid_buttoncover_gap * (1-gap));
 357 }
 358
 359 module DemoProfiles(){ ////toplevel
 360   LidEdgeProfile();
 361   %EdgeProfile();
 362   KeeperProfile();
 363
 364   translate([20,0]) {
 365     LidEdgeProfile();
 366     %EdgeProfile();
 367
 368     demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
 369
 370     color("blue") ButtonCoverProfile();
 371     color("red") {
 372       rectfromto(bppQ, demopoint_QR);
 373       rectfromto(bppR, demopoint_QR);
 374     }
 375   }
 376
 377   translate([-20,0]) {
 378     ButtonPlanForDemo("blue",    0, 0,0);
 379     ButtonPlanForDemo("red",    -1, 1,0);
 380     ButtonPlanForDemo("yellow", -2, 0,1);
 381     ButtonPlanForDemo("blue",   -3, 1,1);
 382   }
 383 }
 384
 385 //EdgeProfile();
 386 //KeeperProfile();
 387 //CaseBase();
 388 //%Case();
 389 //Keeper();
 390 //LidEdgeProfile();
 391 //KeeperProfile();
 392 //DemoProfiles();