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 = [ 12.64, 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_shaft_len = 12;
66 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
67 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
68 hingescrew_head_th = 1.38 + 0.75;
69 hingescrew_head_dia = 3.92;
70 lever_cover_th = 0.75;
77 buttonishleg_default_l_is_fudge = 10;
79 strut_min_at_end = 1.5;
82 hinge_x_postscrew_gap = 0.75;
83 hinge_x_arms_gap = 0.35;
84 hinge_r_arms_gap = 0.55;
86 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
88 // ---------- calculated ----------
90 phone_width = (phone + bumper*2)[0];
91 phone_height = (phone + bumper*2)[1];
93 inside_br = [phone_width, -phone_height];
95 //echo(camera_pos_tl + bumper,
96 // camera_pos_br + bumper);
98 // ----- could be changed -----
99 lid_buttoncover_gap = lid_gap_x;
100 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
102 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
104 //lid_lip_overlap_width xxx bad name = ;
105 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
108 epp1 = [0, -phone_edge_thick];
109 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
110 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
111 epp3 = epp2i + [10, 0];
112 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
113 epp4 = epp5 + [-1,0] * case_th_side;
116 kppd = kppe + [1,0] * keeper_inner_width;
117 kppc = kppd + [0,1] * keeper_th_z;
118 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
119 kppf = kppe - [0,1] * keeper_inner_height;
120 kppa = [ kppb[0], kppf[1] ];
122 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
123 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
125 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
127 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
128 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
132 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
133 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
134 bppS = [ epp1[0], bppR[1] ];
135 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
136 bppP = bppQ + [0,1] * lid_buttoncover_gap;
137 bppO = [ bppN[0], bppP[1] ];
138 bppL = lpp10 + [5,0];
139 bppK = [ bppL[0], bppN[1] ];
140 bppJ = [ bppN[0], bppL[1] ];
143 hp_rn = hingescrew_nut_dia/2;
144 hp_r2 = hp_rn + lever_cover_th;
145 hp_rs = hingescrew_shaft_dia/2;
146 hp_r1 = hp_rs + hingemount_th;
149 hppS = epp2o + [0,-1] * case_th_bottom;
150 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
152 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
153 0.5 * (hppU + hppS)[1] ];
154 hppT = hppM + 0.5 * [0,+1] * hp_k;
155 hppB = hppM + 0.5 * [0,-1] * hp_k;
157 // hinge elevation x coords
159 hingescrew_portion_len =
160 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
162 hex20 = max(epp2o[0],
164 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
165 hex21 = hex20 + hingescrew_portion_len;
166 hex22 = hex21 - hinge_x_gap;
167 hex23 = hex22 + hingescrew_portion_len;
168 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
169 echo(hex20, hex21, hex22, hex23, hex24);
170 echo(hingescrew_portion_len);
172 // ---------- modules ----------
174 module KeeperProfile(slant=0){
175 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
176 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
179 module EdgeProfile(){
182 translate(epp3) square(case_th_bottom*2, center=true);
183 circleat(epp2o, r=case_th_bottom);
184 circleat(epp1, r=case_th_side);
185 rectfromto(epp0, epp4);
187 polygon([ epp5 + [0,10],
194 module LidEdgeProfile(){
203 circleat(lpp12, r=lp_r12);
204 rectfromto( lpp12 + [-10, 0],
205 lpp12 + [+10, +10] );
209 module ButtonCoverProfile(){
211 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
219 module ButtonPlan(l, deep, cut){
221 (cut ? 0 : lid_buttoncover_gap);
224 (deep ? lid_buttoncover_overlap : 0);
226 C = [0,0]; // by definition
230 B0 = C + [0,-1] * button_cutout_depth;
231 B1 = B0 + [0,1] * epsilon;
233 r0 = 0.5 * (T[1] - B0[1]);
234 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
235 H = A + [0,-1] * delta;
241 E1 = E0 + [1,0] * epsilon;
243 I0 = [ E0[0], H[1] ];
244 I1 = [ E1[0], H[1] ];
247 for (m=[0,1]) mirror([m,0])
248 circleat(H, r0 - epsilon);
250 for (m=[0,1]) mirror([m,0]) {
260 circleat(D, r0 + epsilon);
265 module Flip_rhs(yn=[0,1]) {
267 translate([phone_width/2, 0, 0])
268 mirror([$rhsflip,0,0])
269 translate([-phone_width/2, 0, 0])
274 module Flip_bot(yn=[0,1]) {
276 translate([0, -phone_height/2, 0])
277 mirror([0, $botflip, 0])
278 translate([0, phone_height/2, 0])
283 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
286 translate([0, -phone_cnr_rad, 0])
288 linear_extrude(height = phone_height - phone_cnr_rad*2)
292 Flip_rhs() Flip_bot() {
293 translate([+1,-1] * phone_cnr_rad)
298 translate([-1,0] * phone_cnr_rad)
300 rectfromto([0,-20],[10,20]);
302 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
308 translate([ phone_width - phone_cnr_rad, 0,0 ])
310 linear_extrude(height = phone_width - phone_cnr_rad*2)
314 translate([0,0, fill_zstart])
315 mirror([0,0, fill_downwards])
316 linear_extrude(height = fill_th)
317 rectfromto([+1,-1] * phone_cnr_rad,
318 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
321 module CaseAperture(pos, dia, $fn) {
323 translate([ pos[0] + bumper[0],
326 rotate([-90, theta, 0])
327 cylinder(r = dia/2 / cos(theta),
331 module SideButton(y, y_ref_sign, l){
333 // +1 measured from top of actual phone to top of button
334 // -1 measured from bottom of actual phone to bottom of button
335 // 0 y is centre of button in coordinate system
337 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
338 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
341 translate([0, eff_y, 0])
345 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
346 $button_leg_only = true;
347 SideButton(y, y_ref_sign, l) children();
351 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
352 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
353 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
354 Flip_rhs( ) LidButtonishLeg(20, -1) children();
355 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
358 module Struts(x_start, z_min, th){
359 // if th is negative, starts at z_min and works towards -ve z
360 // and object should then be printed other way up
361 for (i= [1 : 1 : case_struts_count]) {
365 mirror([0,0, th<0 ? 1 : 0])
367 -phone_height * i / (case_struts_count+1),
368 case_struts_solid_below])
369 linear_extrude(height= abs(th)
370 -(case_struts_solid_below+case_struts_solid_above))
371 rectfromto([ x_start, -0.5 * case_struts_width ],
372 [ phone_width - x_start, +0.5 * case_struts_width ]);
376 module OrdinaryRearAperture(rhs,bot, pos){
377 Flip_rhs(rhs) Flip_bot(bot)
380 translate(pos + bumper)
384 module OrdinaryRearApertures(){
386 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
387 rectfromto(-rearspeaker_gap,
388 rearspeaker_size + rearspeaker_gap);
390 // finger hole to remove phone
391 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
393 scale(fingerpushhole_dias)
397 module RearCameraAperture(){
400 linear_extrude(height = 20)
403 rectfromto(camera_pos_tl, camera_pos_br);
406 module HingeLidProfile(){
408 circleat(hppT, hp_r1);
409 circleat(lpp12, lp_r12);
417 module HingeBaseProfile(){
420 circleat(hppB, hp_r1);
421 circleat(epp2o, case_th_bottom);
422 circleat(hppB + [10,0], hp_r1);
424 polygon([epp5, epp1, epp2i, epp3, bppL]);
428 module HingeLeverOuterProfile(){
430 circleat(hppT, hp_r2);
431 circleat(hppB, hp_r2);
435 module HingeLeverInnerProfile(){
436 for (c = [hppT, hppB]) {
441 circleat(hppB, hp_rn);
445 module HingePortion(x0,x1){
446 Flip_rhs() Flip_bot(1)
450 linear_extrude(height=x1-x0)
455 AroundEdges(epp3[1], case_th_bottom, 1)
459 module Case(){ ////toplevel
464 // ledge (fixed keeper)
467 linear_extrude(height = phone_height + phone_cnr_rad * 2)
470 // outline of the whole case, to stop it protruding
471 translate([0,0, -25])
472 linear_extrude(height = 50)
474 // Flip_rhs() // actually, we only care about the LH
476 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
480 HingePortion(hex20, hex21) HingeBaseProfile();
485 translate([0, -phone_cnr_rad, 0])
487 linear_extrude(height = phone_height + phone_cnr_rad * 2)
490 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
491 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
495 RearCameraAperture();
497 // struts (invisible, because they're buried in the case)
498 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
505 linear_extrude(height= 20)
506 ButtonPlan($button_l, 0,1);
507 if ($button_leg_only)
509 translate([phone_width/2, -400, kppe[1]])
510 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
512 translate([0,0, -bppR[0]])
513 linear_extrude(height= 20)
514 ButtonPlan($button_l, 1,1);
518 // apertures along top edge
519 CaseAperture(jack_pos, jack_dia, 8);
521 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
523 OrdinaryRearApertures();
525 // gaps for the lid's hinge arms
526 HingePortion(hex20 - hinge_x_arms_gap,
527 hex21 + hinge_x_arms_gap)
530 circle(r= hinge_r_arms_gap, $fn= 8);
533 // screw holes in the hinge arms
538 module Lid(){ ////toplevel
541 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
549 linear_extrude(height= 20)
550 ButtonPlan($button_l, 1,0);
552 translate([0,0,-100])
553 linear_extrude(height= 200)
554 ButtonCoverProfile();
559 HingePortion(hex20, hex21) HingeLidProfile();
561 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
563 // screw holes in the hinge arms
568 module HingeLever(){ ////toplevel
570 // outer body, positive
571 HingePortion(hex22, hex22 + phone_width/2)
572 HingeLeverOuterProfile();
574 // space for the screws
575 HingePortion(hex23, hex24)
576 HingeLeverInnerProfile();
580 module TestSelectLength(){
581 translate([-30, -200, -20])
582 cube([30 + 15, 250, 40]);
585 module TestLength(){ ////toplevel
592 module TestLengthRight(){ ////toplevel
600 module TestSelectWidth(){
601 translate([-30, -(phone_height - 25), -20])
606 module TestWidth(){ ////toplevel
613 module TestLidWidthPrint(){ ////toplevel
614 rotate([0,180.0]) intersection(){
620 module TestSelectRearAperture(){
624 cube([42, 2, 1], center=true);
628 module TestSelectCamera(){
630 TestSelectRearAperture()
631 RearCameraAperture();
632 cube([0.1, 50, 0.1]);
636 module TestSelectOrdinaryRearApertures(){
637 TestSelectRearAperture()
638 OrdinaryRearApertures();
641 module TestCamera(){ ////toplevel
648 module TestLidByCamera(){ ////toplevel
655 module TestLidByCameraPrint(){ ////toplevel
656 rotate([180,0,0]) TestLidByCamera();
659 module DemoByCamera(){ ////toplevel
660 color("blue") TestLidByCamera();
661 color("red") TestCamera();
664 module OneKeeper(){ ////toplevel
665 translate([0, -phone_cnr_rad, 0])
667 linear_extrude(height = phone_height - phone_cnr_rad * 2)
671 module OneKeeperPrint(){ ////toplevel
676 module LidPrint(){ ////toplevel
681 module TestSelectFrame(){
682 include = [1,-1] * (epp2i[0] + 4);
685 cube(1000, center=true);
686 translate([0,0, -100])
687 linear_extrude(height=200)
688 rectfromto(include, inside_br - include);
692 module TestFrameCase(){ ////toplevel
698 TestSelectOrdinaryRearApertures();
703 module TestFrameLidPrint(){ ////toplevel
704 rotate([0,180,0]) intersection(){
710 module Keeper(){ ////toplevel
715 module ButtonPlanForDemo(z, deep, cut){
717 ButtonPlan(8, deep, cut);
720 module DemoHingeScrews(){
721 Flip_rhs() Flip_bot(1){
722 for (c= [ hppT, hppB ])
728 cylinder( r= hingescrew_shaft_dia/2,
729 h = hingescrew_shaft_len+0.2 );
732 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
737 module DemoFrame(){ ////toplevel
738 color("red") TestFrameCase();
739 color("blue") intersection(){ Lid(); TestSelectFrame(); }
740 color("black") DemoHingeScrews();
744 module DemoHingedFrame(){ ///toplevel
745 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
747 color("red") TestFrameCase();
748 translate([0,0, -2*hp_k])
749 color("blue") intersection(){ Lid(); TestSelectFrame(); }
751 translate(hinge_origin)
753 translate(-hinge_origin) {
754 color("orange") HingeLever();
755 color("black") DemoHingeScrews();
759 module DemoHinge(){ ////toplevel
761 translate([0,0, -hp_k*3])
765 module DemoProfiles(){ ////toplevel
769 translate([0,0,-1]) color("black") KeeperProfile(1);
775 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
777 color("blue") ButtonCoverProfile();
779 rectfromto(bppQ, demopoint_QR);
780 rectfromto(bppR, demopoint_QR);
785 color("black") ButtonPlanForDemo(-2, 0,1);
786 color("red" ) ButtonPlanForDemo(-4, 1,1);
787 color("blue") ButtonPlanForDemo(-6, 1,0);
790 translate([0, -30]) {
793 color("blue") HingeLidProfile();
794 color("red") HingeBaseProfile();
795 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
796 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();