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;
68 foldover_lever_gap = 0.50;
70 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
71 hingescrew_shaft_len = 12;
72 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
73 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
74 hingescrew_head_th = 1.38 + 0.75;
75 hingescrew_head_dia = 3.92;
76 lever_cover_th = 0.75;
83 buttonishleg_default_l_is_fudge = 10;
85 hinge_base_slope = 1.5; // bigger is steeper
87 strut_min_at_end = 1.5;
90 hinge_x_postscrew_gap = 0.75;
91 hinge_x_arms_gap = 0.35;
92 hinge_r_arms_gap = 0.55;
94 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
100 catch_finger_height = 1.5;
101 catch_finger_depth = 2.5;
103 // ---------- calculated ----------
105 phone_width = (phone + bumper*2)[0];
106 phone_height = (phone + bumper*2)[1];
108 inside_br = [phone_width, -phone_height];
110 //echo(camera_pos_tl + bumper,
111 // camera_pos_br + bumper);
113 // ----- could be changed -----
114 lid_buttoncover_gap = lid_gap_x;
115 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
117 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
119 //lid_lip_overlap_width xxx bad name = ;
120 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
123 epp1 = [0, -phone_edge_thick];
124 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
125 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
126 epp3 = epp2i + [10, 0];
127 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
128 epp4 = epp5 + [-1,0] * case_th_side;
131 kppd = kppe + [1,0] * keeper_inner_width;
132 kppc = kppd + [0,1] * keeper_th_z;
133 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
134 kppf = kppe - [0,1] * keeper_inner_height;
135 kppa = [ kppb[0], kppf[1] ];
137 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
138 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
140 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
142 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
143 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
147 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
148 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
149 bppS = [ epp1[0], bppR[1] ];
150 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
151 bppP = bppQ + [0,1] * lid_buttoncover_gap;
152 bppO = [ bppN[0], bppP[1] ];
153 bppL = lpp10 + [5,0];
154 bppK = [ bppL[0], bppN[1] ];
155 bppJ = [ bppN[0], bppL[1] ];
158 hp_rn = hingescrew_nut_dia/2;
159 hp_r2_min = hp_rn + lever_cover_th;
160 hp_rs = hingescrew_shaft_dia/2;
161 hp_r1_min = hp_rs + hingemount_th;
163 hp_r1 = max(hp_r1_min, hp_r2_min);
167 hppS = epp2o + [0,-1] * case_th_bottom;
168 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
170 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
171 0.5 * (hppU + hppS)[1] ];
172 hppT = [ hppM[0], hppU[1] - hp_r1 ];
173 hppB = hppT + [0,-1] * hp_k;
175 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
176 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
177 hppE = [ hppE_x, hppE_y ];
179 // hinge elevation x coords
181 hingescrew_portion_len =
182 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
184 hex20 = max(epp2o[0],
186 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
187 hex21 = hex20 + hingescrew_portion_len;
188 hex22 = hex21 - hinge_x_gap;
189 hex23 = hex22 + hingescrew_portion_len;
190 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
191 echo(hex20, hex21, hex22, hex23, hex24);
192 echo(hingescrew_portion_len);
197 cppA = cppJ + [lid_gap_x, -lid_gap_z];
198 cppB = [ epp0[0], cppA[1] ];
199 cppP = [ epp4[0], cppJ[1] ];
201 cppS = cppJ + [0,-1] * catch_len;
202 cppD = [ cppA[0], cppS[1] + catch_slop ];
203 cppC = [ cppB[0], cppD[1] ];
204 cppT = cppS + [1,0] * catch_depth;
205 cppU = cppT + [0,-1] * catch_height;
206 cppV = [ cppS[0], cppU[1] - catch_height ];
208 cppR = 0.5*(cppP + cppJ);
210 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
212 cppV[1] - (catch_finger_height - cp_rQ) ];
213 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
215 // ---------- modules ----------
217 module KeeperProfile(slant=0){
218 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
219 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
222 module EdgeProfile(){
225 translate(epp3) square(case_th_bottom*2, center=true);
226 circleat(epp2o, r=case_th_bottom);
227 circleat(epp1, r=case_th_side);
228 rectfromto(epp0, epp4);
230 polygon([ epp5 + [0,10],
237 module LidEdgeProfile(){
246 circleat(lpp12, r=lp_r12);
247 rectfromto( lpp12 + [-10, 0],
248 lpp12 + [+10, +10] );
252 module ButtonCoverProfile(){
254 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
262 module ButtonPlan(l, deep, cut){
264 (cut ? 0 : lid_buttoncover_gap);
267 (deep ? lid_buttoncover_overlap : 0);
269 C = [0,0]; // by definition
273 B0 = C + [0,-1] * button_cutout_depth;
274 B1 = B0 + [0,1] * epsilon;
276 r0 = 0.5 * (T[1] - B0[1]);
277 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
278 H = A + [0,-1] * delta;
284 E1 = E0 + [1,0] * epsilon;
286 I0 = [ E0[0], H[1] ];
287 I1 = [ E1[0], H[1] ];
290 for (m=[0,1]) mirror([m,0])
291 circleat(H, r0 - epsilon);
293 for (m=[0,1]) mirror([m,0]) {
303 circleat(D, r0 + epsilon);
308 module CatchCatchProfile(){
310 for (c=[ cppR, cppQ ])
314 circleat(lpp12, lp_r12);
315 circleat(lpp12 + [5,0], lp_r12);
316 rectfromto(cppP, cppP + [5,0.1]);
318 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
321 module CatchCutProfile(){
333 module Flip_rhs(yn=[0,1]) {
335 translate([phone_width/2, 0, 0])
336 mirror([$rhsflip,0,0])
337 translate([-phone_width/2, 0, 0])
342 module Flip_bot(yn=[0,1]) {
344 translate([0, -phone_height/2, 0])
345 mirror([0, $botflip, 0])
346 translate([0, phone_height/2, 0])
351 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
354 translate([0, -phone_cnr_rad, 0])
356 linear_extrude(height = phone_height - phone_cnr_rad*2)
360 Flip_rhs() Flip_bot() {
361 translate([+1,-1] * phone_cnr_rad)
366 translate([-1,0] * phone_cnr_rad)
368 rectfromto([0,-20],[10,20]);
370 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
376 translate([ phone_width - phone_cnr_rad, 0,0 ])
378 linear_extrude(height = phone_width - phone_cnr_rad*2)
382 translate([0,0, fill_zstart])
383 mirror([0,0, fill_downwards])
384 linear_extrude(height = fill_th)
385 rectfromto([+1,-1] * phone_cnr_rad,
386 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
389 module CaseAperture(pos, dia, $fn) {
391 translate([ pos[0] + bumper[0],
394 rotate([-90, theta, 0])
395 cylinder(r = dia/2 / cos(theta),
399 module SideButton(y, y_ref_sign, l){
401 // +1 measured from top of actual phone to top of button
402 // -1 measured from bottom of actual phone to bottom of button
403 // 0 y is centre of button in coordinate system
405 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
406 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
409 translate([0, eff_y, 0])
413 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
414 $button_leg_only = true;
415 SideButton(y, y_ref_sign, l) children();
419 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
420 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
421 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
422 Flip_rhs( ) LidButtonishLeg(20, -1) children();
423 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
426 module Struts(x_start, z_min, th){
427 // if th is negative, starts at z_min and works towards -ve z
428 // and object should then be printed other way up
429 for (i= [1 : 1 : case_struts_count]) {
433 mirror([0,0, th<0 ? 1 : 0])
435 -phone_height * i / (case_struts_count+1),
436 case_struts_solid_below])
437 linear_extrude(height= abs(th)
438 -(case_struts_solid_below+case_struts_solid_above))
439 rectfromto([ x_start, -0.5 * case_struts_width ],
440 [ phone_width - x_start, +0.5 * case_struts_width ]);
444 module OrdinaryRearAperture(rhs,bot, pos){
445 Flip_rhs(rhs) Flip_bot(bot)
448 translate(pos + bumper)
456 linextr(-epp2i[0], 60)
457 translate([0.5 * phone_width, 0, 0])
458 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
459 [+microusb_width/2, epp0[1] + -microusb_above]);
463 module OrdinaryRearApertures(){
465 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
466 rectfromto(-rearspeaker_gap,
467 rearspeaker_size + rearspeaker_gap);
469 // finger hole to remove phone
470 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
472 scale(fingerpushhole_dias)
476 module RearCameraAperture(){
479 linear_extrude(height = 20)
482 rectfromto(camera_pos_tl, camera_pos_br);
485 module HingeLidProfile(){
487 circleat(hppT, hp_r1);
488 circleat(lpp12, lp_r12);
496 module HingeBaseProfile(){
499 circleat(hppB, hp_r1);
500 circleat(hppE, hp_r1);
501 circleat(epp2o, case_th_bottom);
502 circleat(hppB + [10,0], hp_r1);
504 polygon([epp5, epp1, epp2i, epp3, bppL]);
508 module HingeLeverOuterProfile(){
510 circleat(hppT, hp_r2);
511 circleat(hppB, hp_r2);
515 module HingeLeverInnerProfile(){
516 for (c = [hppT, hppB]) {
521 circleat(hppB, hp_rn);
526 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
527 translate(hinge_origin)
529 translate(-hinge_origin)
533 module HingePortion(x0,x1){
534 Flip_rhs() Flip_bot(1)
538 linear_extrude(height=x1-x0)
543 AroundEdges(epp3[1], case_th_bottom, 1)
547 module Case(){ ////toplevel
552 // ledge (fixed keeper)
555 linear_extrude(height = phone_height + phone_cnr_rad * 2)
558 // outline of the whole case, to stop it protruding
559 translate([0,0, -25])
560 linear_extrude(height = 50)
562 // Flip_rhs() // actually, we only care about the LH
564 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
568 HingePortion(hex20, hex21) HingeBaseProfile();
573 translate([0, -phone_cnr_rad, 0])
575 linear_extrude(height = phone_height + phone_cnr_rad * 2)
578 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
579 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
583 RearCameraAperture();
585 // struts (invisible, because they're buried in the case)
586 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
593 linear_extrude(height= 20)
594 ButtonPlan($button_l, 0,1);
595 if ($button_leg_only)
597 translate([phone_width/2, -400, kppe[1]])
598 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
600 translate([0,0, -bppR[0]])
601 linear_extrude(height= 20)
602 ButtonPlan($button_l, 1,1);
606 // apertures along top edge
607 CaseAperture(jack_pos, jack_dia, 8);
609 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
611 OrdinaryRearApertures();
615 // gaps for the lid's hinge arms
616 HingePortion(hex20 - hinge_x_arms_gap,
617 hex21 + hinge_x_arms_gap)
620 circle(r= hinge_r_arms_gap, $fn= 8);
623 // screw holes in the hinge arms
628 module Lid(){ ////toplevel
631 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
639 linear_extrude(height= 20)
640 ButtonPlan($button_l, 1,0);
642 translate([0,0,-100])
643 linear_extrude(height= 200)
644 ButtonCoverProfile();
649 HingePortion(hex20, hex21) HingeLidProfile();
651 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
653 // screw holes in the hinge arms
658 module HingeLever(){ ////toplevel
660 // outer body, positive
661 HingePortion(hex22, hex22 + phone_width/2)
662 HingeLeverOuterProfile();
664 // space for the screws
665 HingePortion(hex23, hex24)
666 HingeLeverInnerProfile();
668 // bores for the screws
671 // space for the charging cable
673 Flip_hinge() MicroUSB();
677 module HingeLeverPrint(){ ////toplevel
682 module TestSelectLength(){
683 translate([-30, -200, -20])
684 cube([30 + 15, 250, 40]);
687 module TestLength(){ ////toplevel
694 module TestLengthRight(){ ////toplevel
702 module TestSelectWidth(){
703 translate([-30, -(phone_height - 25), -20])
708 module TestWidth(){ ////toplevel
715 module TestLidWidthPrint(){ ////toplevel
716 rotate([0,180.0]) intersection(){
722 module TestSelectRearAperture(){
726 cube([42, 2, 1], center=true);
730 module TestSelectCamera(){
732 TestSelectRearAperture()
733 RearCameraAperture();
734 cube([0.1, 50, 0.1]);
738 module TestSelectOrdinaryRearApertures(){
739 TestSelectRearAperture()
740 OrdinaryRearApertures();
743 module TestCamera(){ ////toplevel
750 module TestLidByCamera(){ ////toplevel
757 module TestLidByCameraPrint(){ ////toplevel
758 rotate([180,0,0]) TestLidByCamera();
761 module DemoByCamera(){ ////toplevel
762 color("blue") TestLidByCamera();
763 color("red") TestCamera();
766 module OneKeeper(){ ////toplevel
767 translate([0, -phone_cnr_rad, 0])
769 linear_extrude(height = phone_height - phone_cnr_rad * 2)
773 module OneKeeperPrint(){ ////toplevel
778 module LidPrint(){ ////toplevel
783 module TestSelectFrame(){
784 include = [1,-1] * (epp2i[0] + 4);
787 cube(1000, center=true);
788 translate([0,0, -100])
789 linear_extrude(height=200)
790 rectfromto(include, inside_br - include);
794 module TestFrameCase(){ ////toplevel
800 TestSelectOrdinaryRearApertures();
805 module TestFrameLidPrint(){ ////toplevel
806 rotate([0,180,0]) intersection(){
812 module Keeper(){ ////toplevel
817 module ButtonPlanForDemo(z, deep, cut){
819 ButtonPlan(8, deep, cut);
822 module HingeScrews(){
823 Flip_rhs() Flip_bot(1){
824 for (c= [ hppT, hppB ])
830 cylinder( r= hingescrew_shaft_dia/2,
831 h = hingescrew_shaft_len+0.2 );
834 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
839 module DemoFrame(){ ////toplevel
840 color("red") TestFrameCase();
841 color("blue") intersection(){ Lid(); TestSelectFrame(); }
842 color("black") HingeScrews();
846 module DemoHingedFrame(){ ///toplevel
847 color("red") TestFrameCase();
848 translate([0,0, -2*hp_k])
849 color("blue") intersection(){ Lid(); TestSelectFrame(); }
852 color("orange") HingeLever();
853 color("black") HingeScrews();
857 module DemoHinge(){ ////toplevel
859 translate([0,0, -hp_k*3])
863 module DemoProfiles(){ ////toplevel
867 translate([0,0,-1]) color("black") KeeperProfile(1);
873 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
875 color("blue") ButtonCoverProfile();
877 rectfromto(bppQ, demopoint_QR);
878 rectfromto(bppR, demopoint_QR);
883 color("black") ButtonPlanForDemo(-2, 0,1);
884 color("red" ) ButtonPlanForDemo(-4, 1,1);
885 color("blue") ButtonPlanForDemo(-6, 1,0);
888 translate([0, -30]) {
891 color("blue") HingeLidProfile();
892 color("red") HingeBaseProfile();
893 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
894 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
897 translate([20,-30]) {
900 //translate([0,0,1]) CatchCutProfile();
901 color("blue") CatchCatchProfile();
902 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }