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