5 phone = [ 75.0, 145.0 ];
7 bumper = [ 0.250, -0.025 ];
8 // ^ One side. Overall size is increased by twice this.
9 // If no bumpers, is the gap around the phone.
13 button_cutout_depth = 9;
15 phone_edge_thick = 9.0;
16 phone_total_thick = 12.0;
17 phone_backside_slope_inner = 1.5; // larger means shallower
18 phone_backside_slope_outer = 1.0; // larger means shallower
20 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
21 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
23 jack_pos = [ 13.92, 7.96 ];
24 jack_dia = 9.1 + .5; // some jack I had lying around
26 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
27 noisecancelmic_dia = 1.75;
29 fingerpushhole_dias = [ 14, 17 ];
31 rearspeaker_pos_bl = [ 14.92, 18.72 ];
32 rearspeaker_size = [ 3.76, 7.36 ];
39 case_struts_count = 6;
40 case_struts_solid_below = 1.00;
41 case_struts_solid_above = 0.75;
42 case_struts_width = 0.10;
46 keeper_inner_width = 2.75;
47 keeper_inner_height = 2.75;
48 keeper_slant_slope = 2; // larger means steeper
50 keeper_gap_z_top = 0.25;
51 keeper_gap_z_bot = 0.75;
53 keeper_gap_x_holes = 0.75;
62 foldover_lever_gap = 0.50;
64 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
65 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
66 lever_cover_th = 0.75;
73 buttonishleg_default_l_is_fudge = 10;
75 strut_min_at_end = 1.5;
77 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
79 // ---------- calculated ----------
81 phone_width = (phone + bumper*2)[0];
82 phone_height = (phone + bumper*2)[1];
84 inside_br = [phone_width, -phone_height];
86 //echo(camera_pos_tl + bumper,
87 // camera_pos_br + bumper);
89 // ----- could be changed -----
90 lid_buttoncover_gap = lid_gap_x;
91 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
93 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
95 //lid_lip_overlap_width xxx bad name = ;
96 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
99 epp1 = [0, -phone_edge_thick];
100 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
101 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
102 epp3 = epp2i + [10, 0];
103 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
104 epp4 = epp5 + [-1,0] * case_th_side;
107 kppd = kppe + [1,0] * keeper_inner_width;
108 kppc = kppd + [0,1] * keeper_th_z;
109 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
110 kppf = kppe - [0,1] * keeper_inner_height;
111 kppa = [ kppb[0], kppf[1] ];
113 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
114 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
116 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
118 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
119 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
123 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
124 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
125 bppS = [ epp1[0], bppR[1] ];
126 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
127 bppP = bppQ + [0,1] * lid_buttoncover_gap;
128 bppO = [ bppN[0], bppP[1] ];
129 bppL = lpp10 + [5,0];
130 bppK = [ bppL[0], bppN[1] ];
131 bppJ = [ bppN[0], bppL[1] ];
134 hp_rn = hingescrew_nut_dia/2;
135 hp_r2 = hp_rn + lever_cover_th;
136 hp_rs = hingescrew_shaft_dia/2;
137 hp_r1 = hp_rs + hingemount_th;
140 hppS = epp2o + [0,-1] * case_th_bottom;
141 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
143 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
144 0.5 * (hppU + hppS)[1] ];
145 hppT = hppM + 0.5 * [0,+1] * hp_k;
146 hppB = hppM + 0.5 * [0,-1] * hp_k;
148 // ---------- modules ----------
150 module KeeperProfile(slant=0){
151 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
152 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
155 module EdgeProfile(){
158 translate(epp3) square(case_th_bottom*2, center=true);
159 circleat(epp2o, r=case_th_bottom);
160 circleat(epp1, r=case_th_side);
161 rectfromto(epp0, epp4);
163 polygon([ epp5 + [0,10],
170 module LidEdgeProfile(){
179 circleat(lpp12, r=lp_r12);
180 rectfromto( lpp12 + [-10, 0],
181 lpp12 + [+10, +10] );
185 module ButtonCoverProfile(){
187 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
195 module ButtonPlan(l, deep, cut){
197 (cut ? 0 : lid_buttoncover_gap);
200 (deep ? lid_buttoncover_overlap : 0);
202 C = [0,0]; // by definition
206 B0 = C + [0,-1] * button_cutout_depth;
207 B1 = B0 + [0,1] * epsilon;
209 r0 = 0.5 * (T[1] - B0[1]);
210 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
211 H = A + [0,-1] * delta;
217 E1 = E0 + [1,0] * epsilon;
219 I0 = [ E0[0], H[1] ];
220 I1 = [ E1[0], H[1] ];
223 for (m=[0,1]) mirror([m,0])
224 circleat(H, r0 - epsilon);
226 for (m=[0,1]) mirror([m,0]) {
236 circleat(D, r0 + epsilon);
241 module CaseBase_rhsflip(yn=[0,1]) {
243 translate([phone_width/2, 0, 0])
244 mirror([$rhsflip,0,0])
245 translate([-phone_width/2, 0, 0])
250 module CaseBase_botflip(yn=[0,1]) {
252 translate([0, -phone_height/2, 0])
253 mirror([0, $botflip, 0])
254 translate([0, phone_height/2, 0])
259 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
262 translate([0, -phone_cnr_rad, 0])
264 linear_extrude(height = phone_height - phone_cnr_rad*2)
268 CaseBase_rhsflip() CaseBase_botflip() {
269 translate([+1,-1] * phone_cnr_rad)
274 translate([-1,0] * phone_cnr_rad)
276 rectfromto([0,-20],[10,20]);
278 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
284 translate([ phone_width - phone_cnr_rad, 0,0 ])
286 linear_extrude(height = phone_width - phone_cnr_rad*2)
290 translate([0,0, fill_zstart])
291 mirror([0,0, fill_downwards])
292 linear_extrude(height = fill_th)
293 rectfromto([+1,-1] * phone_cnr_rad,
294 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
297 module CaseAperture(pos, dia, $fn) {
299 translate([ pos[0] + bumper[0],
302 rotate([-90, theta, 0])
303 cylinder(r = dia/2 / cos(theta),
307 module SideButton(y, y_ref_sign, l){
309 // +1 measured from top of actual phone to top of button
310 // -1 measured from bottom of actual phone to bottom of button
311 // 0 y is centre of button in coordinate system
313 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
314 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
317 translate([0, eff_y, 0])
321 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
322 $button_leg_only = true;
323 SideButton(y, y_ref_sign, l) children();
327 CaseBase_rhsflip([1]) SideButton(15.580, +1, 8.9) children(); // power
328 CaseBase_rhsflip([1]) SideButton(48.700, -1, 8.920) children(); // camera
329 CaseBase_rhsflip([0]) SideButton(30.800, +1, 21.96) children(); // volume
330 CaseBase_rhsflip( ) LidButtonishLeg(20, -1) children();
331 // CaseBase_rhsflip([0]) LidButtonishLeg(20, +1, 20) children();
334 module Struts(x_start, z_min, th){
335 // if th is negative, starts at z_min and works towards -ve z
336 // and object should then be printed other way up
337 for (i= [1 : 1 : case_struts_count]) {
341 mirror([0,0, th<0 ? 1 : 0])
343 -phone_height * i / (case_struts_count+1),
344 case_struts_solid_below])
345 linear_extrude(height= abs(th)
346 -(case_struts_solid_below+case_struts_solid_above))
347 rectfromto([ x_start, -0.5 * case_struts_width ],
348 [ phone_width - x_start, +0.5 * case_struts_width ]);
352 module OrdinaryRearAperture(rhs,bot, pos){
353 CaseBase_rhsflip(rhs) CaseBase_botflip(bot)
356 translate(pos + bumper)
360 module OrdinaryRearApertures(){
362 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
363 rectfromto(-rearspeaker_gap,
364 rearspeaker_size + rearspeaker_gap);
366 // finger hole to remove phone
367 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
369 scale(fingerpushhole_dias)
373 module RearCameraAperture(){
374 CaseBase_rhsflip([1])
376 linear_extrude(height = 20)
379 rectfromto(camera_pos_tl, camera_pos_br);
382 module HingeLidProfile(){
384 circleat(hppT, hp_r1);
385 circleat(lpp12, lp_r12);
393 module HingeBaseProfile(){
396 circleat(hppB, hp_r1);
397 circleat(epp2o, case_th_bottom);
398 circleat(hppB + [10,0], hp_r1);
400 polygon([epp5, epp1, epp2i, epp3, bppL]);
404 module HingeLeverOuterProfile(){
406 circleat(hppT, hp_r2);
407 circleat(hppB, hp_r2);
411 module HingeLeverInnerProfile(){
412 for (c = [hppT, hppB]) {
417 circleat(hppB, hp_rn);
421 module HingePortion(){
426 AroundEdges(epp3[1], case_th_bottom, 1)
430 module Case(){ ////toplevel
435 // ledge (fixed keeper)
438 linear_extrude(height = phone_height + phone_cnr_rad * 2)
441 // outline of the whole case, to stop it protruding
442 translate([0,0, -25])
443 linear_extrude(height = 50)
445 // CaseBase_rhsflip() // actually, we only care about the LH
447 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
451 // HingePortion(hex20, hex21) HingerBaseProfile();
456 translate([0, -phone_cnr_rad, 0])
458 linear_extrude(height = phone_height + phone_cnr_rad * 2)
461 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
462 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
466 RearCameraAperture();
468 // struts (invisible, because they're buried in the case)
469 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
476 linear_extrude(height= 20)
477 ButtonPlan($button_l, 0,1);
478 if ($button_leg_only)
480 translate([phone_width/2, -400, kppe[1]])
481 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
483 translate([0,0, -bppR[0]])
484 linear_extrude(height= 20)
485 ButtonPlan($button_l, 1,1);
489 // apertures along top edge
490 CaseAperture(jack_pos, jack_dia, 8);
491 CaseBase_rhsflip([1])
492 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
494 OrdinaryRearApertures();
498 module Lid(){ ////toplevel
501 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
509 linear_extrude(height= 20)
510 ButtonPlan($button_l, 1,0);
512 translate([0,0,-100])
513 linear_extrude(height= 200)
514 ButtonCoverProfile();
518 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
522 module TestSelectLength(){
523 translate([-30, -200, -20])
524 cube([30 + 15, 250, 40]);
527 module TestLength(){ ////toplevel
534 module TestLengthRight(){ ////toplevel
542 module TestSelectWidth(){
543 translate([-30, -(phone_height - 25), -20])
548 module TestWidth(){ ////toplevel
555 module TestLidWidthPrint(){ ////toplevel
556 rotate([0,180.0]) intersection(){
562 module TestSelectRearAperture(){
566 cube([42, 2, 1], center=true);
570 module TestSelectCamera(){
572 TestSelectRearAperture()
573 RearCameraAperture();
574 cube([0.1, 50, 0.1]);
578 module TestSelectOrdinaryRearApertures(){
579 TestSelectRearAperture()
580 OrdinaryRearApertures();
583 module TestCamera(){ ////toplevel
590 module TestLidByCamera(){ ////toplevel
597 module TestLidByCameraPrint(){ ////toplevel
598 rotate([180,0,0]) TestLidByCamera();
601 module DemoByCamera(){ ////toplevel
602 color("blue") TestLidByCamera();
603 color("red") TestCamera();
606 module OneKeeper(){ ////toplevel
607 translate([0, -phone_cnr_rad, 0])
609 linear_extrude(height = phone_height - phone_cnr_rad * 2)
613 module OneKeeperPrint(){ ////toplevel
618 module LidPrint(){ ////toplevel
623 module TestSelectFrame(){
624 include = [1,-1] * (epp2i[0] + 4);
627 cube(1000, center=true);
628 translate([0,0, -100])
629 linear_extrude(height=200)
630 rectfromto(include, inside_br - include);
634 module TestFrameCase(){ ////toplevel
640 TestSelectOrdinaryRearApertures();
645 module TestFrameLidPrint(){ ////toplevel
646 rotate([0,0,180]) intersection(){
652 module Keeper(){ ////toplevel
657 module ButtonPlanForDemo(z, deep, cut){
659 ButtonPlan(8, deep, cut);
662 module DemoProfiles(){ ////toplevel
666 translate([0,0,-1]) color("black") KeeperProfile(1);
672 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
674 color("blue") ButtonCoverProfile();
676 rectfromto(bppQ, demopoint_QR);
677 rectfromto(bppR, demopoint_QR);
682 color("black") ButtonPlanForDemo(-2, 0,1);
683 color("red" ) ButtonPlanForDemo(-4, 1,1);
684 color("blue") ButtonPlanForDemo(-6, 1,0);
687 translate([0, -30]) {
690 color("blue") HingeLidProfile();
691 color("red") HingeBaseProfile();
692 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
693 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();