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 = [ 15, 18 ];
31 rearspeaker_pos_bl = [ 12.64, 18.72 ];
32 rearspeaker_size = [ 3.76, 7.36 ];
34 microusb_above = 3.27 - 0.25;
36 microusb_width = 16.12 + 0.25;
43 case_struts_count = 6;
44 case_struts_solid_below = 1.00;
45 case_struts_solid_above = 0.75;
46 case_struts_width = 0.10;
50 keeper_inner_width = 2.75;
51 keeper_inner_height = 2.75;
52 keeper_slant_slope = 2; // larger means steeper
54 keeper_gap_z_top = 0.25;
55 keeper_gap_z_bot = 0.75;
57 keeper_gap_x_holes = 0.75;
66 foldover_lever_gap = 0.50;
68 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
69 hingescrew_shaft_len = 12;
70 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
71 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
72 hingescrew_head_th = 1.38 + 0.75;
73 hingescrew_head_dia = 3.92;
74 lever_cover_th = 0.75;
81 buttonishleg_default_l_is_fudge = 10;
83 hinge_base_slope = 1.5; // bigger is steeper
85 strut_min_at_end = 1.5;
88 hinge_x_postscrew_gap = 0.75;
89 hinge_x_arms_gap = 0.35;
90 hinge_r_arms_gap = 0.55;
92 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
94 // ---------- calculated ----------
96 phone_width = (phone + bumper*2)[0];
97 phone_height = (phone + bumper*2)[1];
99 inside_br = [phone_width, -phone_height];
101 //echo(camera_pos_tl + bumper,
102 // camera_pos_br + bumper);
104 // ----- could be changed -----
105 lid_buttoncover_gap = lid_gap_x;
106 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
108 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
110 //lid_lip_overlap_width xxx bad name = ;
111 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
114 epp1 = [0, -phone_edge_thick];
115 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
116 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
117 epp3 = epp2i + [10, 0];
118 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
119 epp4 = epp5 + [-1,0] * case_th_side;
122 kppd = kppe + [1,0] * keeper_inner_width;
123 kppc = kppd + [0,1] * keeper_th_z;
124 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
125 kppf = kppe - [0,1] * keeper_inner_height;
126 kppa = [ kppb[0], kppf[1] ];
128 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
129 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
131 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
133 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
134 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
138 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
139 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
140 bppS = [ epp1[0], bppR[1] ];
141 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
142 bppP = bppQ + [0,1] * lid_buttoncover_gap;
143 bppO = [ bppN[0], bppP[1] ];
144 bppL = lpp10 + [5,0];
145 bppK = [ bppL[0], bppN[1] ];
146 bppJ = [ bppN[0], bppL[1] ];
149 hp_rn = hingescrew_nut_dia/2;
150 hp_r2_min = hp_rn + lever_cover_th;
151 hp_rs = hingescrew_shaft_dia/2;
152 hp_r1_min = hp_rs + hingemount_th;
154 hp_r1 = max(hp_r1_min, hp_r2_min);
158 hppS = epp2o + [0,-1] * case_th_bottom;
159 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
161 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
162 0.5 * (hppU + hppS)[1] ];
163 hppT = [ hppM[0], hppU[1] - hp_r1 ];
164 hppB = hppT + [0,-1] * hp_k;
166 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
167 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
168 hppE = [ hppE_x, hppE_y ];
170 // hinge elevation x coords
172 hingescrew_portion_len =
173 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
175 hex20 = max(epp2o[0],
177 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
178 hex21 = hex20 + hingescrew_portion_len;
179 hex22 = hex21 - hinge_x_gap;
180 hex23 = hex22 + hingescrew_portion_len;
181 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
182 echo(hex20, hex21, hex22, hex23, hex24);
183 echo(hingescrew_portion_len);
185 // ---------- modules ----------
187 module KeeperProfile(slant=0){
188 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
189 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
192 module EdgeProfile(){
195 translate(epp3) square(case_th_bottom*2, center=true);
196 circleat(epp2o, r=case_th_bottom);
197 circleat(epp1, r=case_th_side);
198 rectfromto(epp0, epp4);
200 polygon([ epp5 + [0,10],
207 module LidEdgeProfile(){
216 circleat(lpp12, r=lp_r12);
217 rectfromto( lpp12 + [-10, 0],
218 lpp12 + [+10, +10] );
222 module ButtonCoverProfile(){
224 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
232 module ButtonPlan(l, deep, cut){
234 (cut ? 0 : lid_buttoncover_gap);
237 (deep ? lid_buttoncover_overlap : 0);
239 C = [0,0]; // by definition
243 B0 = C + [0,-1] * button_cutout_depth;
244 B1 = B0 + [0,1] * epsilon;
246 r0 = 0.5 * (T[1] - B0[1]);
247 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
248 H = A + [0,-1] * delta;
254 E1 = E0 + [1,0] * epsilon;
256 I0 = [ E0[0], H[1] ];
257 I1 = [ E1[0], H[1] ];
260 for (m=[0,1]) mirror([m,0])
261 circleat(H, r0 - epsilon);
263 for (m=[0,1]) mirror([m,0]) {
273 circleat(D, r0 + epsilon);
278 module Flip_rhs(yn=[0,1]) {
280 translate([phone_width/2, 0, 0])
281 mirror([$rhsflip,0,0])
282 translate([-phone_width/2, 0, 0])
287 module Flip_bot(yn=[0,1]) {
289 translate([0, -phone_height/2, 0])
290 mirror([0, $botflip, 0])
291 translate([0, phone_height/2, 0])
296 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
299 translate([0, -phone_cnr_rad, 0])
301 linear_extrude(height = phone_height - phone_cnr_rad*2)
305 Flip_rhs() Flip_bot() {
306 translate([+1,-1] * phone_cnr_rad)
311 translate([-1,0] * phone_cnr_rad)
313 rectfromto([0,-20],[10,20]);
315 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
321 translate([ phone_width - phone_cnr_rad, 0,0 ])
323 linear_extrude(height = phone_width - phone_cnr_rad*2)
327 translate([0,0, fill_zstart])
328 mirror([0,0, fill_downwards])
329 linear_extrude(height = fill_th)
330 rectfromto([+1,-1] * phone_cnr_rad,
331 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
334 module CaseAperture(pos, dia, $fn) {
336 translate([ pos[0] + bumper[0],
339 rotate([-90, theta, 0])
340 cylinder(r = dia/2 / cos(theta),
344 module SideButton(y, y_ref_sign, l){
346 // +1 measured from top of actual phone to top of button
347 // -1 measured from bottom of actual phone to bottom of button
348 // 0 y is centre of button in coordinate system
350 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
351 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
354 translate([0, eff_y, 0])
358 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
359 $button_leg_only = true;
360 SideButton(y, y_ref_sign, l) children();
364 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
365 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
366 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
367 Flip_rhs( ) LidButtonishLeg(20, -1) children();
368 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
371 module Struts(x_start, z_min, th){
372 // if th is negative, starts at z_min and works towards -ve z
373 // and object should then be printed other way up
374 for (i= [1 : 1 : case_struts_count]) {
378 mirror([0,0, th<0 ? 1 : 0])
380 -phone_height * i / (case_struts_count+1),
381 case_struts_solid_below])
382 linear_extrude(height= abs(th)
383 -(case_struts_solid_below+case_struts_solid_above))
384 rectfromto([ x_start, -0.5 * case_struts_width ],
385 [ phone_width - x_start, +0.5 * case_struts_width ]);
389 module OrdinaryRearAperture(rhs,bot, pos){
390 Flip_rhs(rhs) Flip_bot(bot)
393 translate(pos + bumper)
401 linextr(-epp2i[0], 60)
402 translate([0.5 * phone_width, 0, 0])
403 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
404 [+microusb_width/2, epp0[1] + -microusb_above]);
408 module OrdinaryRearApertures(){
410 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
411 rectfromto(-rearspeaker_gap,
412 rearspeaker_size + rearspeaker_gap);
414 // finger hole to remove phone
415 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
417 scale(fingerpushhole_dias)
421 module RearCameraAperture(){
424 linear_extrude(height = 20)
427 rectfromto(camera_pos_tl, camera_pos_br);
430 module HingeLidProfile(){
432 circleat(hppT, hp_r1);
433 circleat(lpp12, lp_r12);
441 module HingeBaseProfile(){
444 circleat(hppB, hp_r1);
445 circleat(hppE, hp_r1);
446 circleat(epp2o, case_th_bottom);
447 circleat(hppB + [10,0], hp_r1);
449 polygon([epp5, epp1, epp2i, epp3, bppL]);
453 module HingeLeverOuterProfile(){
455 circleat(hppT, hp_r2);
456 circleat(hppB, hp_r2);
460 module HingeLeverInnerProfile(){
461 for (c = [hppT, hppB]) {
466 circleat(hppB, hp_rn);
471 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
472 translate(hinge_origin)
474 translate(-hinge_origin)
478 module HingePortion(x0,x1){
479 Flip_rhs() Flip_bot(1)
483 linear_extrude(height=x1-x0)
488 AroundEdges(epp3[1], case_th_bottom, 1)
492 module Case(){ ////toplevel
497 // ledge (fixed keeper)
500 linear_extrude(height = phone_height + phone_cnr_rad * 2)
503 // outline of the whole case, to stop it protruding
504 translate([0,0, -25])
505 linear_extrude(height = 50)
507 // Flip_rhs() // actually, we only care about the LH
509 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
513 HingePortion(hex20, hex21) HingeBaseProfile();
518 translate([0, -phone_cnr_rad, 0])
520 linear_extrude(height = phone_height + phone_cnr_rad * 2)
523 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
524 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
528 RearCameraAperture();
530 // struts (invisible, because they're buried in the case)
531 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
538 linear_extrude(height= 20)
539 ButtonPlan($button_l, 0,1);
540 if ($button_leg_only)
542 translate([phone_width/2, -400, kppe[1]])
543 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
545 translate([0,0, -bppR[0]])
546 linear_extrude(height= 20)
547 ButtonPlan($button_l, 1,1);
551 // apertures along top edge
552 CaseAperture(jack_pos, jack_dia, 8);
554 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
556 OrdinaryRearApertures();
560 // gaps for the lid's hinge arms
561 HingePortion(hex20 - hinge_x_arms_gap,
562 hex21 + hinge_x_arms_gap)
565 circle(r= hinge_r_arms_gap, $fn= 8);
568 // screw holes in the hinge arms
573 module Lid(){ ////toplevel
576 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
584 linear_extrude(height= 20)
585 ButtonPlan($button_l, 1,0);
587 translate([0,0,-100])
588 linear_extrude(height= 200)
589 ButtonCoverProfile();
594 HingePortion(hex20, hex21) HingeLidProfile();
596 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
598 // screw holes in the hinge arms
603 module HingeLever(){ ////toplevel
605 // outer body, positive
606 HingePortion(hex22, hex22 + phone_width/2)
607 HingeLeverOuterProfile();
609 // space for the screws
610 HingePortion(hex23, hex24)
611 HingeLeverInnerProfile();
613 // bores for the screws
616 // space for the charging cable
618 Flip_hinge() MicroUSB();
622 module HingeLeverPrint(){ ////toplevel
627 module TestSelectLength(){
628 translate([-30, -200, -20])
629 cube([30 + 15, 250, 40]);
632 module TestLength(){ ////toplevel
639 module TestLengthRight(){ ////toplevel
647 module TestSelectWidth(){
648 translate([-30, -(phone_height - 25), -20])
653 module TestWidth(){ ////toplevel
660 module TestLidWidthPrint(){ ////toplevel
661 rotate([0,180.0]) intersection(){
667 module TestSelectRearAperture(){
671 cube([42, 2, 1], center=true);
675 module TestSelectCamera(){
677 TestSelectRearAperture()
678 RearCameraAperture();
679 cube([0.1, 50, 0.1]);
683 module TestSelectOrdinaryRearApertures(){
684 TestSelectRearAperture()
685 OrdinaryRearApertures();
688 module TestCamera(){ ////toplevel
695 module TestLidByCamera(){ ////toplevel
702 module TestLidByCameraPrint(){ ////toplevel
703 rotate([180,0,0]) TestLidByCamera();
706 module DemoByCamera(){ ////toplevel
707 color("blue") TestLidByCamera();
708 color("red") TestCamera();
711 module OneKeeper(){ ////toplevel
712 translate([0, -phone_cnr_rad, 0])
714 linear_extrude(height = phone_height - phone_cnr_rad * 2)
718 module OneKeeperPrint(){ ////toplevel
723 module LidPrint(){ ////toplevel
728 module TestSelectFrame(){
729 include = [1,-1] * (epp2i[0] + 4);
732 cube(1000, center=true);
733 translate([0,0, -100])
734 linear_extrude(height=200)
735 rectfromto(include, inside_br - include);
739 module TestFrameCase(){ ////toplevel
745 TestSelectOrdinaryRearApertures();
750 module TestFrameLidPrint(){ ////toplevel
751 rotate([0,180,0]) intersection(){
757 module Keeper(){ ////toplevel
762 module ButtonPlanForDemo(z, deep, cut){
764 ButtonPlan(8, deep, cut);
767 module HingeScrews(){
768 Flip_rhs() Flip_bot(1){
769 for (c= [ hppT, hppB ])
775 cylinder( r= hingescrew_shaft_dia/2,
776 h = hingescrew_shaft_len+0.2 );
779 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
784 module DemoFrame(){ ////toplevel
785 color("red") TestFrameCase();
786 color("blue") intersection(){ Lid(); TestSelectFrame(); }
787 color("black") HingeScrews();
791 module DemoHingedFrame(){ ///toplevel
792 color("red") TestFrameCase();
793 translate([0,0, -2*hp_k])
794 color("blue") intersection(){ Lid(); TestSelectFrame(); }
797 color("orange") HingeLever();
798 color("black") HingeScrews();
802 module DemoHinge(){ ////toplevel
804 translate([0,0, -hp_k*3])
808 module DemoProfiles(){ ////toplevel
812 translate([0,0,-1]) color("black") KeeperProfile(1);
818 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
820 color("blue") ButtonCoverProfile();
822 rectfromto(bppQ, demopoint_QR);
823 rectfromto(bppR, demopoint_QR);
828 color("black") ButtonPlanForDemo(-2, 0,1);
829 color("red" ) ButtonPlanForDemo(-4, 1,1);
830 color("blue") ButtonPlanForDemo(-6, 1,0);
833 translate([0, -30]) {
836 color("blue") HingeLidProfile();
837 color("red") HingeBaseProfile();
838 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
839 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();