fairphone-case.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 phone = [ 75.0, 145.0 ];
   6
   7 prop_buildout_less = 3;
   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 = 4;
 121 prop_side_gap = 0.75; // each side
 122 prop_lidrecess_behind = 0.75;
 123 prop_caserecess_behind = 0.75;
 124 prop_caserecess_taper = 0.45; // one side only
 125 prop_prop_gap = 0.5;
 126 prop_prong_heel_slope = 0.5;
 127
 128 // ---------- calculated ----------
 129
 130 phone_width =  (phone + bumper*2)[0];
 131 phone_height = (phone + bumper*2)[1];
 132
 133 inside_br = [phone_width, -phone_height];
 134
 135 prop_prong_h = prop_main_th;
 136
 137 //echo(camera_pos_tl + bumper,
 138 //     camera_pos_br + bumper);
 139
 140 // ----- could be changed -----
 141 lid_buttoncover_gap = lid_gap_x;
 142 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
 143
 144 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
 145
 146 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
 147
 148 //prop_nose_len = case_th_lid - prop_recess_under;
 149 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
 150 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
 151
 152
 153 //lid_lip_overlap_width xxx bad name = ;
 154 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
 155
 156 epp0 = [0,0];
 157 epp1 = [0, -phone_edge_thick];
 158 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
 159 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
 160 epp3 = epp2i + [10, 0];
 161 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
 162 epp4 = epp5 + [-1,0] * case_th_side;
 163
 164 kppe = [0,0];
 165 kppd = kppe + [1,0] * keeper_inner_width;
 166 kppc = kppd + [0,1] * keeper_th_z;
 167 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
 168 kppf = kppe - [0,1] * keeper_inner_height;
 169 kppa = [ kppb[0], kppf[1] ];
 170
 171 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
 172 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 173
 174 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
 175
 176 lpp12 = [ epp4[0] + lp_r12,    lpp11[1] ];
 177 lpp13 = [ lpp12[0],            lpp12[1] + lp_r12 ];
 178
 179 case_bottom_z = epp2o[1] - case_th_bottom;
 180
 181 // button profile
 182 bppM = epp4 + [0,5];
 183 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
 184 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
 185 bppS = [ epp1[0], bppR[1] ];
 186 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
 187 bppP = bppQ + [0,1] * lid_buttoncover_gap;
 188 bppO = [ bppN[0], bppP[1] ];
 189 bppL = lpp10 + [5,0];
 190 bppK = [ bppL[0], bppN[1] ];
 191 bppJ = [ bppN[0], bppL[1] ];
 192
 193 // hinge plan
 194 hp_rn = hingescrew_nut_dia/2;
 195 hp_r2_min = hp_rn + lever_cover_th;
 196 hp_rs = hingescrew_shaft_dia/2;
 197 hp_r1_min = hp_rs + hingemount_th;
 198
 199 hp_r1 = max(hp_r1_min, hp_r2_min);
 200 hp_r2 = hp_r1;
 201
 202 hppU = lpp13;
 203 hppS = epp2o + [0,-1] * case_th_bottom;
 204 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
 205
 206 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
 207          0.5 * (hppU + hppS)[1] ];
 208 hppT = [ hppM[0], hppU[1] - hp_r1 ];
 209 hppB = hppT + [0,-1] * hp_k;
 210
 211 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
 212 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
 213 hppE = [ hppE_x, hppE_y ];
 214
 215 // hinge elevation x coords
 216
 217 hingescrew_portion_len =
 218   0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
 219
 220 hex20 = max(epp2o[0],
 221             phone_cnr_rad,
 222             kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
 223 hex21 = hex20 + hingescrew_portion_len;
 224 hex22 = hex21 + hinge_x_gap;
 225 hex23 = hex22 + hingescrew_portion_len
 226   - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
 227 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
 228 //echo(hex20, hex21, hex22, hex23, hex24);
 229 //echo(hingescrew_portion_len);
 230
 231 // catch
 232
 233 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
 234 cppA = cppJ + [lid_gap_x, -lid_gap_z];
 235 cppB = [ epp0[0], cppA[1] ];
 236 cppP = [ epp4[0], cppJ[1] ];
 237
 238 cppS = cppJ + [0,-1] * catch_len;
 239 cppD = [ cppA[0], cppS[1] + catch_slop ];
 240 cppC = [ cppB[0], cppD[1] ];
 241 cppT = cppS + [1,0] * catch_depth;
 242 cppU = cppT + [0,-1] * catch_height;
 243 cppV = [ cppS[0], cppU[1] - catch_depth ];
 244
 245 cppR = 0.5*(cppP + cppJ);
 246
 247 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
 248 cppQ = [ cppR[0],
 249          cppV[1] - (catch_finger_height - cp_rQ) ];
 250 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
 251
 252 // prop recess in case
 253
 254 prop_x_pos = phone_width/2;
 255
 256 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
 257
 258 prc_r1 = prop_end_dia/2;
 259 prc_r3 = prc_r1 + prop_recess_slop;
 260
 261 prcp2 = [ epp4[0] + prop_buildout_less,
 262           case_bottom_z ];
 263
 264 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
 265
 266 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
 267           epp2i[1] - prc_r3 - prop_recess_under];
 268
 269 // prop recess in lid
 270
 271 prl_r10 = prop_end_dia/2;
 272 prl_r10o = prl_r10 + prop_recess_slop;
 273
 274 prlp10 = lpp10 + [1,1] * prl_r10o
 275   + [1,0] * prop_lidrecess_behind
 276   + [0,1] * prop_recess_under;
 277
 278 // prop
 279
 280 $prpp10 = [0,0];
 281 $prpp11 = [0, prop_taper_len];
 282
 283 $prp_r10 = prl_r10;
 284
 285 // ---------- modules ----------
 286
 287 module KeeperProfile(slant=0){
 288   use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
 289   polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
 290 }
 291
 292 module EdgeProfile(){
 293   difference(){
 294     hull(){
 295       translate(epp3) square(case_th_bottom*2, center=true);
 296       circleat(epp2o, r=case_th_bottom);
 297       circleat(epp1, r=case_th_side);
 298       rectfromto(epp0, epp4);
 299     }
 300     polygon([ epp5 + [0,10],
 301               epp1,
 302               epp2i,
 303               epp3 + [10,0] ]);
 304   }
 305 }
 306
 307 module LidEdgeProfile(){
 308   polygon([ lpp10,
 309             lpp11,
 310             lpp12,
 311             lpp13,
 312             lpp13 + [10, 0],
 313             lpp10 + [10, 0]
 314             ]);
 315   intersection(){
 316     circleat(lpp12, r=lp_r12);
 317     rectfromto( lpp12 + [-10,   0],
 318                 lpp12 + [+10, +10] );
 319   }
 320 }
 321
 322 module ButtonCoverProfile(){
 323   intersection(){
 324     polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
 325     hull(){
 326       EdgeProfile();
 327       LidEdgeProfile();
 328     }
 329   }
 330 }
 331
 332 module ButtonPlan(l, deep, cut){
 333   epsilon =
 334     (cut  ? 0 : lid_buttoncover_gap);
 335
 336   delta =
 337     (deep ? lid_buttoncover_overlap : 0);
 338
 339   C = [0,0]; // by definition
 340   T = [ 0, epp4[1] ];
 341   G = T + [0,10];
 342
 343   B0 = C + [0,-1] * button_cutout_depth;
 344   B1 = B0 + [0,1] * epsilon;
 345
 346   r0 = 0.5 * (T[1] - B0[1]);
 347   A = [  -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
 348   H = A + [0,-1] * delta;
 349
 350   D = A + [-2,0] * r0;
 351   F = D + [0,10];
 352
 353   E0 = 0.5 * (D + A);
 354   E1 = E0 + [1,0] * epsilon;
 355
 356   I0 = [ E0[0], H[1] ];
 357   I1 = [ E1[0], H[1] ];
 358
 359   hull(){
 360     for (m=[0,1]) mirror([m,0])
 361       circleat(H, r0 - epsilon);
 362   }
 363   for (m=[0,1]) mirror([m,0]) {
 364     difference(){
 365       polygon([ E1,
 366                 I1,
 367                 H,
 368                 B1,
 369                 G,
 370                 F,
 371                 D
 372                 ]);
 373       circleat(D, r0 + epsilon);
 374     }
 375   }
 376 }
 377
 378 module CatchCatchProfile(){
 379   hull(){
 380     for (c=[ cppR, cppQ ])
 381       circleat(c, cp_rQ);
 382   }
 383   hull(){
 384     circleat(lpp12, lp_r12);
 385     circleat(lpp12 + [5,0], lp_r12);
 386     rectfromto(cppP, cppP + [5,0.1]);
 387   }
 388   polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
 389 }
 390
 391 module CatchCutProfile(){
 392   polygon([ cppB,
 393             cppA,
 394             cppD,
 395             cppF,
 396             cppF + [0,-10],
 397             cppF + [-10,-10],
 398             lpp12 + [-10,0],
 399             lpp12 + [10,0]
 400             ]);
 401 }
 402
 403 module Flip_rhs(yn=[0,1]) {
 404   for ($rhsflip=yn) {
 405     translate([phone_width/2, 0, 0])
 406       mirror([$rhsflip,0,0])
 407       translate([-phone_width/2, 0, 0])
 408       children();
 409   }
 410 }
 411
 412 module Flip_bot(yn=[0,1]) {
 413   for ($botflip=yn) {
 414     translate([0, -phone_height/2, 0])
 415       mirror([0, $botflip, 0])
 416       translate([0, phone_height/2, 0])
 417       children();
 418   }
 419 }
 420
 421 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
 422   // sides
 423   Flip_rhs(){
 424     translate([0, -phone_cnr_rad, 0])
 425       rotate([90,0,0])
 426       linear_extrude(height = phone_height - phone_cnr_rad*2)
 427       children(0);
 428   }
 429   // corners
 430   Flip_rhs() Flip_bot() {
 431     translate([+1,-1] * phone_cnr_rad)
 432       intersection(){
 433         rotate_extrude()
 434           intersection(){
 435             mirror([1,0,0])
 436               translate([-1,0] * phone_cnr_rad)
 437               children(0);
 438             rectfromto([0,-20],[10,20]);
 439           }
 440         translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
 441           cube([10,10,40]);
 442       }
 443   }
 444   // top and bottom
 445   Flip_bot(){
 446     translate([ phone_width - phone_cnr_rad, 0,0 ])
 447       rotate([90,0,-90])
 448       linear_extrude(height = phone_width - phone_cnr_rad*2)
 449       children(0);
 450   }
 451   // fill
 452   translate([0,0, fill_zstart])
 453     mirror([0,0, fill_downwards])
 454     linear_extrude(height = fill_th)
 455     rectfromto([+1,-1] * phone_cnr_rad,
 456                [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 457 }
 458
 459 module CaseAperture(pos, dia, $fn) {
 460   theta = 180/$fn;
 461   translate([ pos[0] + bumper[0],
 462               -epp2i[0],
 463               -pos[1] ])
 464     rotate([-90, theta, 0])
 465     cylinder(r = dia/2 / cos(theta),
 466              h = 60);
 467 }
 468
 469 module SideButton(y, y_ref_sign, l){
 470   // y_ref_sign:
 471   //   +1  measured from top    of actual phone to top    of button
 472   //   -1  measured from bottom of actual phone to bottom of button
 473   //    0  y is centre of button in coordinate system
 474   $button_l= l;
 475   eff_y = y_ref_sign > 0 ?         -bumper [1] -y -l/2 :
 476           y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
 477           y;
 478   //echo(eff_y);
 479   translate([0, eff_y, 0])
 480     children();
 481 }
 482
 483 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 484   $button_leg_only = true;
 485   SideButton(y, y_ref_sign, l) children();
 486 }
 487
 488 module Buttons(){
 489   Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
 490   Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
 491   Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
 492   Flip_rhs(   ) LidButtonishLeg(14, -1) children();
 493 //  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 494 }
 495
 496 module Struts(x_start, z_min, th){
 497   // if th is negative, starts at z_min and works towards -ve z
 498   // and object should then be printed other way up
 499   for (i= [1 : 1 : case_struts_count]) {
 500     translate([0,
 501                0,
 502                z_min])
 503       mirror([0,0, th<0 ? 1 : 0])
 504       translate([0,
 505                  -phone_height * i / (case_struts_count+1),
 506                  case_struts_solid_below])
 507       linear_extrude(height= abs(th)
 508                      -(case_struts_solid_below+case_struts_solid_above))
 509       rectfromto([               x_start, -0.5 * case_struts_width ],
 510                  [ phone_width - x_start, +0.5 * case_struts_width ]);
 511   }
 512 }
 513
 514 module OrdinaryRearAperture(rhs,bot, pos){
 515   Flip_rhs(rhs) Flip_bot(bot)
 516     linextr(-20, 20)
 517     mirror([0,1])
 518     translate(pos + bumper)
 519     children();
 520 }
 521
 522 module MicroUSB(){
 523   Flip_bot(1){
 524     rotate([90,0,0])
 525       mirror([0,0,1])
 526       linextr(-epp2i[0], 60)
 527       translate([0.5 * phone_width, 0, 0])
 528       rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
 529                  [+microusb_width/2, epp0[1] + -microusb_above]);
 530   }
 531 }
 532
 533 module OrdinaryRearApertures(){
 534   // rear speaker
 535   OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
 536     rectfromto(-rearspeaker_gap,
 537                rearspeaker_size + rearspeaker_gap);
 538
 539   // finger hole to remove phone
 540   if (len(fingerpushhole_dias))
 541     OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
 542                                 phone[1]/2 ])
 543     scale(fingerpushhole_dias)
 544     circle(r= 0.5 );
 545 }
 546
 547 module RearCameraAperture(){
 548   Flip_rhs(1)
 549     mirror([0, 0, 1])
 550     linear_extrude(height = 20)
 551     mirror([0, 1, 0])
 552     translate(bumper)
 553     rectfromto(camera_pos_tl, camera_pos_br);
 554 }
 555
 556 module HingeLidProfile(){
 557   hull(){
 558     circleat(hppT, hp_r1);
 559     circleat(lpp12, lp_r12);
 560     polygon([lpp10,
 561              lpp13 + [2,0],
 562              lpp12,
 563              hppT]);
 564   }
 565 }
 566
 567 module HingeBaseProfile(){
 568   difference(){
 569     hull(){
 570       circleat(hppB, hp_r1);
 571       circleat(hppE, hp_r1);
 572       circleat(epp2o, case_th_bottom);
 573       circleat(hppB + [10,0], hp_r1);
 574     }
 575     polygon([epp5, epp1, epp2i, epp3, bppL]);
 576   }
 577 }
 578
 579 module HingeLeverOuterProfile(){
 580   hull(){
 581     circleat(hppT, hp_r2);
 582     circleat(hppB, hp_r2);
 583   }
 584 }
 585
 586 module HingeLeverInnerProfile(){
 587   for (c = [hppT, hppB]) {
 588     hull()
 589       for (x=[-20,20])
 590         for (y=[0, c[1] - hppM[1]])
 591           translate([x,y])
 592             circleat(c, hp_rn);
 593   }
 594 }
 595
 596 module Flip_hinge(){
 597   hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
 598   translate(hinge_origin)
 599     rotate([180,0,0])
 600     translate(-hinge_origin)
 601     children();
 602 }
 603
 604 module HingePortion(x0,x1){
 605   Flip_rhs() Flip_bot(1)
 606     translate([x0,0,0])
 607     mirror([1,0,0])
 608     rotate([90,0,-90])
 609     linear_extrude(height=x1-x0)
 610     children(0);
 611 }
 612
 613 module CatchPortion(width){
 614   translate([phone_width/2, 0,0])
 615     rotate([90,0,-90])
 616     linextr(-width/2, width/2)
 617     children(0);
 618 }
 619
 620 module CaseBase(){
 621   AroundEdges(epp3[1], case_th_bottom, 1)
 622     EdgeProfile();
 623 }
 624
 625 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
 626
 627 module PropProfileAssignments(gamma){
 628   // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
 629   x = prop_x(gamma);
 630   p = phone_height + prlp10[0] - hppB[0];
 631   b = p + x;
 632
 633   q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
 634   a = q + x;
 635   c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
 636   $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
 637
 638   $prp_theta = 90 - $prp_alpha;
 639   beta = 180 - $prp_alpha - gamma;
 640   psi = 90 - beta;
 641
 642   //echo("abc", a,b,c);
 643
 644   v1 = [ [ cos(psi), -sin(psi) ],    // x
 645          [ sin(psi),  cos(psi) ] ];  // y
 646
 647   $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
 648
 649   $prp_r1 = prc_r1;
 650   $prp_r11 = prop_main_th/2;
 651
 652   $prpp1 = $prpp7 + [1,0] *
 653     // this is approximate, but will do
 654     (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
 655   $prpp3 = $prpp1 +
 656     v1[0] * -$prp_r1 +
 657     v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
 658   $prpp12 = $prpp3 + v1[0] *
 659     (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
 660   $prp_r8 = prop_main_th;
 661   $prpp4 = [ prop_main_th/2, $prpp3[1] ];
 662   $prp_r5 = $prp_r8;
 663   $prpp5 = [ $prpp12[0] - $prp_r5,
 664             $prpp3[1] - prop_prong_h + $prp_r5 ];
 665   $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
 666          prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
 667   $prpp8 = $prpp4 + [0,-1] * $prp_r8;
 668   $prpp9 = $prpp8 + [-1,0] * $prp_r8;
 669
 670   children();
 671 }
 672
 673 module PropProfile(gamma, cut=0, rot=0){ ////toplevel
 674   PropProfileAssignments(gamma){
 675
 676     //#circleat($prpp3,1);
 677     //#circleat($prpp12,1);
 678
 679     if (!cut) {
 680       hull(){
 681         translate($prpp8)
 682           intersection(){
 683             circle($prp_r8);
 684             polygon([[-20,-0], [20,20], [0,0]]);
 685           }
 686         rectfromto($prpp6, $prpp9);
 687         translate($prpp5) intersection(){
 688           circle($prp_r5);
 689           polygon([[-10,-10], [0,0], [10,0]]);
 690         }
 691         rectfromto($prpp12 + [0,-0.1], $prpp3);
 692       }
 693       hull(){
 694         circleat($prpp1, $prp_r1);
 695         rectfromto($prpp12 + [0,-0.1], $prpp3);
 696       }
 697     }
 698     // main shaft
 699     rotate([0,0, rot*-$prp_theta]){
 700       hull(){
 701         extra = cut ? prop_recess_slop : 0;
 702         rectfromto($prpp6, $prpp9);
 703         circleat($prpp11, $prp_r11 + extra);
 704         circleat($prpp10, $prp_r10 + extra);
 705       }
 706     }
 707   }
 708 }
 709
 710 module PropAggregateProfile(){
 711   for (angle = prop_angles)
 712     PropProfile(angle, 0,0);
 713 }
 714
 715 module Prop(){ ////toplevel
 716   hw = prop_main_width/2;
 717   linextr(-hw, +hw)
 718     PropAggregateProfile();
 719 }
 720
 721 module Case(){ ////toplevel
 722   difference(){
 723     union(){
 724       CaseBase();
 725
 726       // ledge (fixed keeper)
 727       Flip_rhs(1-keeper_side) intersection(){
 728         rotate([90, 0, 0])
 729           linear_extrude(height = phone_height + phone_cnr_rad * 2)
 730           KeeperProfile(1);
 731
 732         // outline of the whole case, to stop it protruding
 733         translate([0,0, -25])
 734           linear_extrude(height = 50)
 735           hull()
 736           Flip_bot()
 737           circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
 738       }
 739
 740       // hinge
 741       HingePortion(hex20, hex21) HingeBaseProfile();
 742
 743       // buildout for prop recess
 744       if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
 745         linextr(case_bottom_z, epp2i[1])
 746         hull() {
 747           for (dxs = [-1,+1])
 748             circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
 749                        -epp2o[0] ],
 750                      r = epp2o[0] - prcp2[0]);
 751         }
 752     }
 753
 754     // slot for keeper
 755     Flip_rhs(keeper_side)
 756       translate([0, -phone_cnr_rad, 0])
 757       rotate([90, 0, 0])
 758       linear_extrude(height = phone_height + phone_cnr_rad * 2)
 759       minkowski(){
 760         KeeperProfile();
 761         rectfromto([ -keeper_gap_x,    -keeper_gap_z_bot ],
 762                    [ keeper_gap_x_holes,    +keeper_gap_z_top ]);
 763       }
 764
 765     // front camera
 766     RearCameraAperture();
 767
 768     // struts (invisible, because they're buried in the case)
 769     Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
 770
 771     Buttons(){
 772       mirror([1,0,0])
 773         rotate([90,0,90]) {
 774           if (!($button_leg_only && enable_support))
 775           intersection(){
 776             translate([0,0,-10])
 777               linear_extrude(height= 20)
 778               ButtonPlan($button_l, 0,1);
 779             if ($button_leg_only)
 780               rotate([-90,90,0])
 781                 translate([phone_width/2, -400, kppe[1]])
 782                 mirror([1-abs($rhsflip - keeper_side),0,0])
 783                 cube([400, 800, 50]);
 784             if (enable_support)
 785               rotate([-90,90,0])
 786               translate([-400, -400, kppd[1]])
 787                 mirror([0,0,1])
 788                 cube([800,800,100]);
 789           }
 790           translate([0,0, -bppR[0]])
 791             linear_extrude(height= 20)
 792             ButtonPlan($button_l, 1,1);
 793         }
 794
 795     }
 796
 797     // apertures along top edge
 798     CaseAperture(jack_pos, jack_dia, 8);
 799     Flip_rhs(1)
 800       CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
 801
 802     OrdinaryRearApertures();
 803
 804     MicroUSB();
 805
 806     // gaps for the lid's hinge arms
 807     HingePortion(hex20 - hinge_x_arms_gap,
 808                  hex21 + hinge_x_arms_gap)
 809       minkowski(){
 810         HingeLidProfile();
 811         circle(r= hinge_r_arms_gap, $fn= 8);
 812       }
 813
 814     // screw holes in the hinge arms
 815     HingeScrews();
 816
 817     // catch striker
 818     CatchPortion(catch_width + catch_side_gap*2)
 819       CatchCutProfile();
 820
 821     // prop recess
 822     Flip_rhs(1)
 823       translate([prop_x_pos,0,0])
 824       mirror([0,1,0])
 825       rotate([90,0,90])
 826       linextr(-prop_recess_hw, +prop_recess_hw)
 827       hull(){
 828         for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
 829           circleat(prcp1 + 20*d,
 830                    prc_r3);
 831       }
 832   }
 833 }
 834
 835 module Lid(){ ////toplevel
 836   difference(){
 837     union(){
 838       AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
 839         LidEdgeProfile();
 840
 841       // button covers
 842       Buttons(){
 843         intersection(){
 844           rotate([90,0,90])
 845             translate([0,0,-10])
 846             linear_extrude(height= 20)
 847             ButtonPlan($button_l, 1,0);
 848           rotate([90,0,0])
 849              translate([0,0,-100])
 850             linear_extrude(height= 200)
 851             ButtonCoverProfile();
 852         }
 853       }
 854
 855       // hinge arms
 856       HingePortion(hex20, hex21) HingeLidProfile();
 857
 858       // catch
 859       CatchPortion(catch_width)
 860         CatchCatchProfile();
 861     }
 862     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
 863
 864     // screw holes in the hinge arms
 865     HingeScrews();
 866
 867     // prop recess
 868     translate([prop_x_pos, -prlp10[0], prlp10[1]])
 869       mirror([0,1,0])
 870       rotate([90,0,90])
 871       linextr(-prop_recess_hw, +prop_recess_hw)
 872       hull()
 873       for (pa = prop_angles)
 874         PropProfile(pa, 1,1);
 875   }
 876 }
 877
 878 module HingeLever(){ ////toplevel
 879   difference() {
 880     // outer body, positive
 881     HingePortion(hex22, hex22 + phone_width/2)
 882       HingeLeverOuterProfile();
 883
 884     // space for the screws
 885     HingePortion(hex23, hex24)
 886       HingeLeverInnerProfile();
 887
 888     // bores for the screws
 889     HingeScrews();
 890
 891     // space for the charging cable
 892     MicroUSB();
 893     Flip_hinge() MicroUSB();
 894   }
 895 }
 896
 897 module HingeLeverPrint(){ ////toplevel
 898   rotate([90,0,0])
 899     HingeLever();
 900 }
 901
 902 module TestSelectLength(){
 903   translate([-30, -200, -20])
 904     cube([30 + 15, 250, 40]);
 905 }
 906
 907 module TestLength(){ ////toplevel
 908   intersection(){
 909     Case();
 910     TestSelectLength();
 911   }
 912 }
 913
 914 module TestLengthRight(){ ////toplevel
 915   intersection(){
 916     Case();
 917     Flip_rhs(1)
 918       TestSelectLength();
 919   }
 920 }
 921
 922 module TestSelectWidth(){
 923   translate([-30, -(phone_height - 25), -20])
 924     mirror([0, 1, 0])
 925     cube([200, 50, 40]);
 926 }
 927
 928 module TestWidth(){ ////toplevel
 929   intersection(){
 930     Case();
 931     TestSelectWidth();
 932   }
 933 }
 934
 935 module TestLidWidthPrint(){ ////toplevel
 936   rotate([0,180.0]) intersection(){
 937     Lid();
 938     TestSelectWidth();
 939   }
 940 }
 941
 942 module TestSelectRearAperture(){
 943   minkowski(){
 944     union() children();
 945     translate([20, 0,0])
 946       cube([42, 2, 1], center=true);
 947   }
 948 }
 949
 950 module TestSelectCamera(){
 951   minkowski(){
 952     TestSelectRearAperture()
 953       RearCameraAperture();
 954     cube([0.1, 50, 0.1]);
 955   }
 956 }
 957
 958 module TestSelectOrdinaryRearApertures(){
 959   TestSelectRearAperture()
 960     OrdinaryRearApertures();
 961 }
 962
 963 module TestCamera(){ ////toplevel
 964   intersection(){
 965     Case();
 966     TestSelectCamera();
 967   }
 968 }
 969
 970 module TestLidByCamera(){ ////toplevel
 971   intersection(){
 972     Lid();
 973     TestSelectCamera();
 974   }
 975 }
 976
 977 module TestLidByCameraPrint(){ ////toplevel
 978   rotate([180,0,0]) TestLidByCamera();
 979 }
 980
 981 module DemoByCamera(){ ////toplevel
 982   color("blue") TestLidByCamera();
 983   color("red")  TestCamera();
 984 }
 985
 986 module OneKeeper(){ ////toplevel
 987   translate([0, -phone_cnr_rad, 0])
 988     rotate([90, 0, 0])
 989     linear_extrude(height = phone_height - phone_cnr_rad * 2)
 990     KeeperProfile();
 991 }
 992
 993 module OneKeeperPrint(){ ////toplevel
 994   rotate([0,180,0])
 995     OneKeeper();
 996 }
 997
 998 module LidPrint(){ ////toplevel
 999   rotate([0,180,0])
1000     Lid();
1001 }
1002
1003 module TestSelectFrame(){
1004   include = [1,-1] * (epp2i[0] + 4);
1005
1006   difference(){
1007     cube(1000, center=true);
1008     translate([0,0, -100])
1009       linear_extrude(height=200)
1010       rectfromto(include,  inside_br - include);
1011   }
1012 }
1013
1014 module TestSelectLidFrame(){
1015   TestSelectFrame();
1016 }
1017
1018 module TestFrameCase(){ ////toplevel
1019   intersection(){
1020     Case();
1021     union(){
1022       TestSelectFrame();
1023       TestSelectCamera();
1024       TestSelectOrdinaryRearApertures();
1025     }
1026   }
1027 }
1028
1029 module TestFrameLidPrint(){ ////toplevel
1030   rotate([0,180,0]) intersection(){
1031     Lid();
1032     TestSelectLidFrame();
1033   }
1034 }
1035
1036 module ButtonPlanForDemo(z, deep, cut){
1037   translate([0,0,z])
1038     ButtonPlan(8, deep, cut);
1039 }
1040
1041 module HingeScrews(){
1042   Flip_rhs() Flip_bot(1){
1043     for (c= [ hppT, hppB ])
1044       translate([ hex20,
1045                   -c[0],
1046                   c[1] ]){
1047         rotate([0,90,0])
1048           translate([0,0,-.2])
1049           cylinder( r= hingescrew_shaft_dia/2,
1050                     h = hingescrew_shaft_len+0.2 );
1051         rotate([0,-90,0])
1052           translate([0,0,+.1])
1053           cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1054       }
1055   }
1056 }
1057
1058 module DemoPropAngleSelect(c){
1059   color(c) difference(){
1060     union(){ children(); }
1061     translate([ prop_x_pos, -400, -200 ])
1062       cube([ 400,800,400 ]);
1063   }
1064 }
1065
1066 module DemoPropAngle(ang){
1067   hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1068   hC = [0, -(phone_height - hppB[0]), hppB[1]];
1069
1070   translate(hL)
1071     rotate([ang/2,0,0])
1072     translate(-hL)
1073     translate(hC)
1074     rotate([ang/2,0,0])
1075     translate(-hC) {
1076       DemoPropAngleSelect("red") Case();
1077
1078       color("orange")
1079         translate([prop_x_pos, -prcp1[0], prcp1[1]])
1080         PropProfileAssignments(ang) {
1081           echo($prpp1);
1082           rotate([-$prp_theta, 0, 0])
1083           translate([0, $prpp1[0], -$prpp1[1]])
1084           rotate([90,0,-90])
1085           Prop();
1086         }
1087     }
1088
1089   translate([0,0, -hp_k*2])
1090     DemoPropAngleSelect("blue")
1091     Lid();
1092 }
1093
1094 module DemoPropAngles(){ ////toplevel
1095   for (i=[0 : len(prop_angles)-1])
1096     translate(i * [0, -100, 100])
1097     DemoPropAngle(prop_angles[i]);
1098 }
1099
1100 module DemoFrame(){ ////toplevel
1101   color("red") TestFrameCase();
1102   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1103   color("black") HingeScrews();
1104   %HingeLever();
1105 }
1106
1107 module DemoHingedFrame(){ ///toplevel
1108   color("red") TestFrameCase();
1109   translate([0,0, -2*hp_k])
1110   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1111
1112   Flip_hinge(){
1113     color("orange") HingeLever();
1114     color("black") HingeScrews();
1115   }
1116 }
1117
1118 module DemoHinge(){ ////toplevel
1119   DemoFrame();
1120   translate([0,0, -hp_k*3])
1121     DemoHingedFrame();
1122 }
1123
1124 module DemoProfiles(){ ////toplevel
1125   LidEdgeProfile();
1126   %EdgeProfile();
1127   KeeperProfile();
1128   translate([0,0,-1]) color("black") KeeperProfile(1);
1129
1130   translate([20,0]) {
1131     LidEdgeProfile();
1132     %EdgeProfile();
1133
1134     demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1135
1136     color("blue") ButtonCoverProfile();
1137     color("red") {
1138       rectfromto(bppQ, demopoint_QR);
1139       rectfromto(bppR, demopoint_QR);
1140     }
1141   }
1142
1143   translate([-20,0]) {
1144     color("black") ButtonPlanForDemo(-2, 0,1);
1145     color("red" )  ButtonPlanForDemo(-4, 1,1);
1146     color("blue")  ButtonPlanForDemo(-6, 1,0);
1147   }
1148
1149   translate([0, -30]) {
1150     %LidEdgeProfile();
1151     %EdgeProfile();
1152     color("blue") HingeLidProfile();
1153     color("red")  HingeBaseProfile();
1154     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1155     color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
1156   }
1157
1158   translate([20,-30]) {
1159     %EdgeProfile();
1160     %LidEdgeProfile();
1161     //translate([0,0,1]) CatchCutProfile();
1162     color("blue") CatchCatchProfile();
1163     color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
1164   }
1165
1166   translate([40,-30]) {
1167     difference(){
1168       LidEdgeProfile();
1169       translate(prlp10)
1170         PropProfile(10, 1, 0);
1171     }
1172     translate(prlp10)
1173       PropProfile(15, 0);
1174   }
1175   translate([60,-30]) {
1176     PropAggregateProfile();
1177   }
1178 }
1179
1180 //EdgeProfile();
1181 //KeeperProfile();
1182 //CaseBase();
1183 //%Case();
1184 //Keeper();
1185 //LidEdgeProfile();
1186 //KeeperProfile();
1187 //DemoProfiles();
1188 //PropRecess();