3 // Hard case for Fairphone 2
5 // Copyright 2018 Ian Jackson. There is NO WARRANTY.
6 // See below for full licensing and disclaimer.
10 // 1. You will want to git clone this repository.
12 // 2. Decide about the notification LED aperture. See the variable
13 // led_window_style, below. The default here is "ad-hoc
14 // multi-colour", which can produces a translucent (clear-ish)
15 // window set into the lid, even on a single-nozzle printer.
16 // See "Ad-hoc multi-colour", below.
18 // 3. use "make" to generate the necessary files:
20 // make -j8 fairphone-case.auto.scads `for f in \
26 // ; do echo fairphone-case,$f.auto.stl; done`
28 // 4. Print them. Case and OneKeeperPrint should probably be
31 // For Lid and LidWindowPrint, if you are doing ad-hoc
33 // i. Set up for clear filament
34 // ii. Print LidWindowPrint. Wait for it to finish.
35 // It won't take long. As soon as it finishes, tell
36 // your printer to warm up (so that in fact it does
38 // iii. Leaving the output so far on the printbed, reload
39 // your printer with the main lid colour.
40 // iv. Print LidPrint. You can let this go unattended.
42 // 5. Assemble the hinge. You will need 4x M2 12mm machine screws
43 // and 8x M2 full nuts.
45 // Make sure you get the hinge the right way round. If you're not
47 // openscad fairphone-case,DemoHinge.auto.scad
48 // to see an assembly diagram.
50 // The nuts recess into the hinge. You will want very fine
51 // pliers. As you screw each screw in, add the second nut when
52 // the screw thread emerges from the first - this will be a
53 // locknut. Screw each screw to an appropriate tightness for the
54 // hinge stiffness. You want the lid-side hinge to be stiffer as
55 // that makes closing the case work better.
57 // When you have the stiffness right, tighten the locknuts onto
62 // - To put the phone in, drop its RH side into the RH side of
63 // the case. Then feed the keeper through the small hole.
64 // Feed it right through.
66 // - The optional prop can be used to prop the phone up (in
67 // portrait orientation only right now). See
68 // openscad fairphone-case,DemoPropAngles.auto.scad
70 // Ad-hoc multi-colour
72 // This file is set up to let you make a translucent window using a
73 // single-extruder printer, using a "two print run" technique. This
74 // works well with our Lulzbot TAZ 5 and Aleph Objects' version of
75 // Cura. If you are using a different printer, you may need to
76 // adjust the parameters or try a different technique. In particular,
77 // initial_layer_thick
78 // set so that the window is one layer thick
79 // initial_layer_width
80 // set so that the slicer draws a rectangle around the whole
81 // object, rather than putting a "skirt" or anything inside
83 // If you have a dual-extruder printer, you can set led_window_style
84 // to 2 and do a single print of LidPrint and LidWindowPrint.
86 // Alternatively you can set it to 1 (just a hole) or 0 (no hole).
88 // Thanks to Clare Boothby for the ad-hoc multi-colour technique (and
89 // the parameters for our Lulzbot TAZ 5 and Aleph Objects's Cura).
93 // It might well be possible to adapt this file for other phones.
94 // If you do, let me know how you get on.
97 // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY
99 // Copyright (C)2018 Ian Jackson.
101 // This program for generating a 3D model is free software: you can
102 // redistribute it and/or modify it under the terms of the GNU
103 // General Public License as published by the Free Software
104 // Foundation, either version 3 of the License, or (at your option)
105 // any later version.
107 // This program is distributed in the hope that it will be useful,
108 // but WITHOUT ANY WARRANTY; without even the implied warranty of
109 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
110 // GNU General Public License for more details.
112 // You should have received a copy of the GNU General Public
113 // License along with this program. If not, see
114 // <http://www.gnu.org/licenses/>.
116 // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY
117 // PROTECT YOUR PHONE ! It is your responsibility to decide whether
118 // this case will meet your needs.
123 phone = [ 75.0, 145.0 ];
125 prop_buildout_less = 3;
127 prop_angles = [ 15, 30, 45, 60 ];
129 bumper = [ 0.250, -0.025 ];
130 // ^ One side. Overall size is increased by twice this.
131 // If no bumpers, is the gap around the phone.
135 led_window_style = 3;
137 // 1: simply an opening
138 // 2: opening with separate cover model, for printing in clear (two colour)
139 // 3: like 2 but one-layer window for ad-hoc multi-colour
141 initial_layer_thick = 0.400; // ^ needed for mode 3 only
142 initial_layer_width = 0.750; // ^ needed for mode 3 only
143 multicolour_gap = 0.15; // each side
146 phone_rim_depth = 0.80; // includes allowance for a screen protector
148 button_cutout_depth = 9;
150 phone_edge_thick = 9.0;
151 phone_total_thick = 12.0;
152 phone_backside_slope_inner = 1.5; // larger means shallower
153 phone_backside_slope_outer = 1.0; // larger means shallower
155 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
156 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
158 jack_pos = [ 13.83, 8.485 ];
159 jack_dia = 10.64 + .5; // some jack I had lying around
161 led_pos = [ 13.98, 10.00 ];
163 led_window_ledge = 0.75; // each side
165 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
166 noisecancelmic_dia = 4.00;
168 //fingerpushhole_dias = [ 15, 18 ];
169 fingerpushhole_dias = [];
171 lanyard_half_dia = 1.15;
172 lanyard_entry_rel_breadth = 2;
173 lanyard_channel_len = 15;
174 rearspeaker_pos_bl = [ 12.64, 18.72 ];
175 rearspeaker_size = [ 3.76, 7.36 ];
177 microusb_above = 3.27 - 0.25;
178 microusb_below = 0.0;
179 microusb_width = 16.12 + 1.25;
181 case_th_bottom = 2.5;
186 lid_screen_gap_extra = .66;
188 case_struts_count = 6;
189 case_struts_solid_below = 1.00;
190 case_struts_solid_above = 0.75;
191 case_struts_width = 0.10;
195 keeper_inner_width = 2.75;
196 keeper_inner_height = 2.75;
197 keeper_slant_slope = 2; // larger means steeper
199 keeper_gap_z_top = 0.25;
200 keeper_gap_z_bot = 0.75;
202 keeper_gap_x_holes = 0.75;
204 keeper_side = 0; // 0 = lhs; 1 = rhs
211 lid_edgepart_width = 5.0;
212 lid_buttoncover_thick = 1.3;
213 lid_buttoncover_reinf = 0.65;
216 foldover_lever_gap = 0.50;
218 // properties of the hinge fasteners
219 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
220 hingescrew_shaft_len = 12;
221 hingescrew_fasteners_extra_thick = 0.40;
222 // ^ amount of thread protruding if everything was completely nominal
223 // and we are using two nuts
224 hingescrew_nut_access_dia = 4.72 + 0.50;
225 // ^ washer is 4.72 dia
226 // also, want to get pliers or tiny spanner in to do up locknut
227 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
228 hingescrew_nut_thick = 1.93;
229 hingescrew_head_th = 1.38 + 0.75;
230 hingescrew_head_dia = 3.92;
232 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
234 lever_cover_th = 0.75;
236 hingemount_wd = 4.8725;
241 button_l_fudge = 4.4;
242 buttonishleg_default_l_is_fudge = 10;
244 hinge_base_slope = 1.5; // bigger is steeper
246 strut_min_at_end = 1.5;
249 hinge_x_postscrew_gap = 0.75;
250 hinge_x_arms_gap = 0.35;
251 hinge_r_arms_gap = 0.55;
253 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
255 thumbrecess_depth = 1.3;
256 thumbrecess_width = 16.5;
261 catch_thickness = 1.3;
265 catch_finger_height = 1.5;
266 catch_finger_depth = 2.5;
267 catch_catch_slope = 2.00;
268 catch_close_slope = 3.00;
270 catch_topcurve_r = 5.0;
272 prop_recess_under = 0.50;
273 prop_recess_slop = 0.200; // each side
278 prop_side_gap = 0.75; // each side
279 prop_lidrecess_behind = 0.75;
280 prop_caserecess_behind = 0.75;
281 prop_caserecess_taper = 0.45; // one side only
283 prop_prong_heel_slope = 0.5;
285 lid_fold_clearance_antislop = 0.5;
287 // ---------- calculated ----------
289 phone_width = (phone + bumper*2)[0];
290 phone_height = (phone + bumper*2)[1];
292 inside_br = [phone_width, -phone_height];
294 prop_prong_h = prop_main_th;
296 //echo(camera_pos_tl + bumper,
297 // camera_pos_br + bumper);
299 // ----- could be changed -----
300 lid_buttoncover_gap = lid_gap_x;
301 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
303 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
305 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
307 //prop_nose_len = case_th_lid - prop_recess_under;
308 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
309 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
312 //lid_lip_overlap_width xxx bad name = ;
313 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
316 epp1 = [0, -phone_edge_thick];
317 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
318 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
319 epp3 = epp2i + [10, 0];
320 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
321 epp4 = epp5 + [-1,0] * case_th_side;
324 kppd = kppe + [1,0] * keeper_inner_width;
325 kppc = kppd + [0,1] * keeper_th_z;
326 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
327 kppf = kppe - [0,1] * keeper_inner_height;
328 kppa = [ kppb[0], kppf[1] ];
330 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
331 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
333 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
334 // exact x posn not very important; must extend past end of keeper
337 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
338 + lid_screen_gap_extra ];
339 // ^ beam theory says to maximise force before contact,
340 // the gap below the `beam' (the lid) must be 1/3
341 // the thickness (ie the lid thickness) if the beam
342 // is solid, or 1/2 if it has a top and bottom only.
343 // ours is mostly solid.
345 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
348 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
349 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
351 case_bottom_z = epp2o[1] - case_th_bottom;
355 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
356 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
357 bppS = [ epp1[0], bppR[1] ];
358 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
359 bppP = bppQ + [0,1] * lid_buttoncover_gap;
360 bppO = [ bppN[0], bppP[1] ];
361 bppL = lpp10 + [5,0];
362 bppK = [ bppL[0], bppN[1] ];
363 bppJ = [ bppN[0], bppL[1] ];
364 bppU = [ bppJ[0], lpp12[1] ];
368 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
370 // notification led aperture
372 nla_r0 = led_aperture/2;
373 nla_r1 = nla_r0 + led_window_ledge;
374 nla_r2 = nla_r1 + multicolour_gap;
376 led_window_style >= 3 ? initial_layer_thick :
377 led_window_style >= 2 ? led_window_ledge : 0;
381 hp_rn = hingescrew_nut_access_dia/2;
382 hp_r2_min = hp_rn + lever_cover_th;
383 hp_rs = hingescrew_shaft_dia/2;
384 hp_r1_min = hp_rs + hingemount_th;
386 hp_r1 = max(hp_r1_min, hp_r2_min);
390 hppS = epp2o + [0,-1] * case_th_bottom;
391 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
393 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
394 0.5 * (hppU + hppS)[1] ];
395 hppT = [ hppM[0], hppU[1] - hp_r1 ];
396 hppB = hppT + [0,-1] * hp_k;
398 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
399 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
400 hppE = [ hppE_x, hppE_y ];
402 // hinge elevation x coords
404 hex20 = max(epp2o[0],
406 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
407 hex21 = hex20 + hingemount_wd;
408 hex22 = hex21 + hinge_x_gap;
409 hex27 = hex20 + hingescrew_shaft_len;
410 hex24 = hex27 + hinge_x_postscrew_gap;
411 hex23 = hex27 - (hingescrew_nut_thick*2
412 + hingescrew_fasteners_extra_thick);
413 hex26 = hex23 + hingescrew_nut_thick * 2/3;
415 echo(hex20, hex21, hex22, hex23, hex24);
416 // 6, 10.8725, 10.9975, 13.74, 18.75
417 module chk(act,exp) {
418 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
419 else echo("ok", act);
427 lid_fold_clearance_skew =
428 (lpp10[1] - hppB[1]) /
429 (lpp10[0] - hppB[0]);
431 echo("SK",lid_fold_clearance_skew);
433 // thumb recess (used to be "catch" hence cpp*
435 cppA = epp4 + [thumbrecess_depth, 0];
436 cppB = [ cppA[0], epp1[1] ];
440 ly_r = lanyard_half_dia / 2;
443 ly_theta = -atan2vector(epp2i - epp1);
444 ly_o = epp2i + 3 * ly_r * unitvector2d(epp1 - epp2i);
446 max_case_bottom_edge_thickness =
448 + sin(ly_theta) * (epp2i-epp2o)[0];
450 ly_q_z = -(ly_rc + ly_r);
451 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
453 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
455 // prop recess in case
457 prop_x_pos = phone_width/2;
459 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
461 prc_r1 = prop_end_dia/2;
462 prc_r3 = prc_r1 + prop_recess_slop;
464 prcp2 = [ epp4[0] + prop_buildout_less,
467 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
469 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
470 epp2i[1] - prc_r3 - prop_recess_under];
472 // prop recess in lid
474 prl_r10 = prop_end_dia/2;
475 prl_r10o = prl_r10 + prop_recess_slop;
477 prlp10 = lpp10 + [1,1] * prl_r10o
478 + [1,0] * prop_lidrecess_behind
479 + [0,1] * prop_recess_under;
484 $prpp11 = [0, prop_taper_len];
488 // ---------- modules ----------
490 module AdhocMultiprintFrame(phase, z0, zs) {
491 // from z0 to z0 + zs*layer
492 extra = phase * (initial_layer_width + multicolour_gap) + 5;
493 xextra = extra + -epp4[0];
494 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
495 yextra = extra + -epp4[0];
496 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
497 p0 = [ xrange[0], yrange[0] ];
498 p1 = [ xrange[1], yrange[1] ];
501 mirror([0,0, zs<0 ? 1 : 0])
502 linear_extrude(height= initial_layer_thick)
504 rectfromto(p0 - [1,1] * initial_layer_width,
505 p1 + [1,1] * initial_layer_width);
510 module KeeperProfile(slant=0){
511 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
512 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
515 module EdgeProfile(){
518 translate(epp3) square(case_th_bottom*2, center=true);
519 circleat(epp2o, r=case_th_bottom);
520 circleat(epp1, r=case_th_side);
521 rectfromto(epp0, epp4);
523 polygon([ epp5 + [0,10],
530 module LanyardLanyardProfile(entry=false){
532 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
533 translate(xs * 0.5 * lanyard_half_dia * [1,0])
534 circle(r= lanyard_half_dia/2);
538 module LanyardCurveChannelProfile(){
539 translate([0, -ly_r])
540 LanyardLanyardProfile();
543 module LanyardEntryChannelProfile(){
544 LanyardLanyardProfile(true);
547 module LanyardMainChannelProfile(){
548 LanyardCurveChannelProfile();
550 square(center=true, ly_r * [6, 2]);
552 translate(ly_r * [3 * xs, -1])
557 module LanyardEntryOuterProfile(){
558 circleat([ly_re + ly_r, 0], ly_re);
561 module LanyardEntry(){
567 translate([d_x, 0, q_z]) {
570 rotate_extrude(convexity=10)
573 LanyardCurveChannelProfile();
581 linear_extrude(height=20)
583 LanyardEntryChannelProfile();
585 translate([0, ly_r*2, 0])
587 linear_extrude(height = ly_r*4){
589 rectfromto([d_x, q_z], [ly_r, 0]);
590 circleat([d_x, q_z], ly_rc);
594 translate([0,0,q_z]){
597 translate([0, oec_y, 0]){
599 translate(ly_re * [-1,0,-2])
600 cube(ly_re * [2,1,2]);
601 rotate_extrude(convexity=10)
602 LanyardEntryOuterProfile();
607 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
608 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
613 linear_extrude(height=20)
614 LanyardEntryOuterProfile();
619 module LanyardCutout(l){
621 linear_extrude(height=l)
623 LanyardMainChannelProfile();
626 translate(ee * l * [-1,0])
632 module LidEdgeProfile(){
643 circleat(lpp12, r=lp_r12);
644 rectfromto( lpp12 + [-10, 0],
645 lpp12 + [+10, +10] );
649 module LidEdgeFoldClearanceProfile(){
650 translate([-lid_fold_clearance_antislop, 0])
659 module ButtonCoverProfile(){
661 polygon(concat([ bppM, bppP, bppO, bppJ ],
662 (enable_support && !$button_suppress_over_keeper
663 ? [ bppU, bppV, bppW ] : []),
672 module ButtonPlan(l, deep, cut){
674 (cut ? 0 : lid_buttoncover_gap);
677 (deep ? lid_buttoncover_overlap : 0);
679 C = [0,0]; // by definition
683 B0 = C + [0,-1] * button_cutout_depth;
684 B1 = B0 + [0,1] * epsilon;
686 r0 = 0.5 * (T[1] - B0[1]);
687 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
688 H = A + [0,-1] * delta;
694 E1 = E0 + [1,0] * epsilon;
696 I0 = [ E0[0], H[1] ];
697 I1 = [ E1[0], H[1] ];
700 for (m=[0,1]) mirror([m,0])
701 circleat(H, r0 - epsilon);
703 for (m=[0,1]) mirror([m,0]) {
713 circleat(D, r0 + epsilon);
718 module ButtonCoverReinf(){ ////toplevel
721 linear_extrude(height=0.01)
723 ButtonCoverProfile();
724 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
727 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
728 circle(r= lid_buttoncover_reinf);
729 translate([-20,0]) square(40, center=true);
734 module CatchCutProfile(){
736 polygon([ cppA + [-10,0],
740 circleat(epp1, r=case_th_side);
744 module Flip_rhs(yn=[0,1]) {
746 translate([phone_width/2, 0, 0])
747 mirror([$rhsflip,0,0])
748 translate([-phone_width/2, 0, 0])
753 module Flip_bot(yn=[0,1]) {
755 translate([0, -phone_height/2, 0])
756 mirror([0, $botflip, 0])
757 translate([0, phone_height/2, 0])
762 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
765 translate([0, -phone_cnr_rad, 0])
767 linear_extrude(height = phone_height - phone_cnr_rad*2)
771 Flip_rhs() Flip_bot() {
772 translate([+1,-1] * phone_cnr_rad)
777 translate([-1,0] * phone_cnr_rad)
779 rectfromto([0,-20],[10,20]);
781 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
787 translate([ phone_width - phone_cnr_rad, 0,0 ])
789 linear_extrude(height = phone_width - phone_cnr_rad*2)
793 translate([0,0, fill_zstart])
794 mirror([0,0, fill_downwards])
795 linear_extrude(height = fill_th)
796 rectfromto([+1,-1] * phone_cnr_rad,
797 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
800 module CaseAperture(pos, dia, $fn) {
802 translate([ pos[0] + bumper[0],
805 rotate([-90, theta, 0])
806 cylinder(r = dia/2 / cos(theta),
810 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
812 // +1 measured from top of actual phone to top of button
813 // -1 measured from bottom of actual phone to bottom of button
814 // 0 y is centre of button in coordinate system
816 $button_suppress_over_keeper= suppress_over_keeper;
817 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
818 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
821 translate([0, eff_y, 0])
825 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
826 $button_leg_only = true;
827 SideButton(y, y_ref_sign, l) children();
831 Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
832 Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
833 Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
834 Flip_rhs( ) LidButtonishLeg(14, -1) children();
835 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
838 module Struts(x_start, z_min, th){
839 // if th is negative, starts at z_min and works towards -ve z
840 // and object should then be printed other way up
841 for (i= [1 : 1 : case_struts_count]) {
845 mirror([0,0, th<0 ? 1 : 0])
847 -phone_height * i / (case_struts_count+1),
848 case_struts_solid_below])
849 linear_extrude(height= abs(th)
850 -(case_struts_solid_below+case_struts_solid_above))
851 rectfromto([ x_start, -0.5 * case_struts_width ],
852 [ phone_width - x_start, +0.5 * case_struts_width ]);
856 module OrdinaryRearAperture(rhs,bot, pos){
857 Flip_rhs(rhs) Flip_bot(bot)
860 translate(pos + bumper)
868 linextr(-epp2i[0], 60)
869 translate([0.5 * phone_width, 0, 0])
870 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
871 [+microusb_width/2, epp0[1] + -microusb_above]);
875 module OrdinaryRearApertures(){
877 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
878 rectfromto(-rearspeaker_gap,
879 rearspeaker_size + rearspeaker_gap);
881 // finger hole to remove phone
882 if (len(fingerpushhole_dias))
883 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
885 scale(fingerpushhole_dias)
889 module RearCameraAperture(){
892 linear_extrude(height = 20)
895 rectfromto(camera_pos_tl, camera_pos_br);
898 module HingeLidProfile(){
900 circleat(hppT, hp_r1);
901 circleat(lpp12, lp_r12);
909 module HingeBaseProfile(){
912 circleat(hppB, hp_r1);
913 circleat(hppE, hp_r1);
914 circleat(epp2o, case_th_bottom);
915 circleat(hppB + [10,0], hp_r1);
917 polygon([epp5, epp1, epp2i, epp3, bppL]);
921 module HingeLeverOuterProfile(){
923 circleat(hppT, hp_r2);
924 circleat(hppB, hp_r2);
928 module HingeLeverInnerProfile(){
930 c = s > 0 ? hppT : hppB;
933 rotate(s<0 ? -40 : 0)
942 module HingeLeverNutProfile(){
943 for (c= [hppB, hppT]) {
945 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
949 module Flip_hinge(doflip=1){
950 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
951 translate(hinge_origin)
952 rotate([doflip*180,0,0])
953 translate(-hinge_origin)
957 module HingePortion(x0,x1){
958 Flip_rhs() Flip_bot(1)
962 linear_extrude(height=x1-x0)
966 module CatchPortion(ztop){
967 width = thumbrecess_width;
968 w = width + catch_topcurve_r*2 + 1;
969 translate([phone_width/2, 0,0]){
974 translate([0, 50, 0])
976 linear_extrude(height=100){
977 for (m=[0,1]) mirror([m,0,0]) {
979 translate([w/2, ztop - catch_topcurve_r])
980 circle(catch_topcurve_r);
981 translate([w/2, -50])
982 square(catch_topcurve_r*2, center=true);
991 AroundEdges(epp3[1], case_th_bottom, 1)
995 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
997 module PropProfileAssignments(gamma){
998 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
1000 p = phone_height + prlp10[0] - hppB[0];
1003 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
1005 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
1006 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
1008 $prp_theta = 90 - $prp_alpha;
1009 beta = 180 - $prp_alpha - gamma;
1012 //echo("abc", a,b,c);
1014 v1 = [ [ cos(psi), -sin(psi) ], // x
1015 [ sin(psi), cos(psi) ] ]; // y
1017 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1020 $prp_r11 = prop_main_th/2;
1022 $prpp1 = $prpp7 + [1,0] *
1023 // this is approximate, but will do
1024 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1027 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1028 $prpp12 = $prpp3 + v1[0] *
1029 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1030 $prp_r8 = prop_main_th;
1031 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1033 $prpp5 = [ $prpp12[0] - $prp_r5,
1034 $prpp3[1] - prop_prong_h + $prp_r5 ];
1035 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1036 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1037 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1038 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1043 module PropProfile(gamma, cut=0, rot=0){
1044 PropProfileAssignments(gamma){
1046 //#circleat($prpp3,1);
1047 //#circleat($prpp12,1);
1054 polygon([[-20,-0], [20,20], [0,0]]);
1056 rectfromto($prpp6, $prpp9);
1057 translate($prpp5) intersection(){
1059 polygon([[-10,-10], [0,0], [10,0]]);
1061 rectfromto($prpp12 + [0,-0.1], $prpp3);
1064 circleat($prpp1, $prp_r1);
1065 rectfromto($prpp12 + [0,-0.1], $prpp3);
1069 rotate([0,0, rot*-$prp_theta]){
1071 extra = cut ? prop_recess_slop : 0;
1072 rectfromto($prpp6, $prpp9);
1073 circleat($prpp11, $prp_r11 + extra);
1074 circleat($prpp10, $prp_r10 + extra);
1080 module PropAggregateProfile(){
1081 for (angle = prop_angles)
1082 PropProfile(angle, 0,0);
1085 module Prop(){ ////toplevel
1086 hw = prop_main_width/2;
1088 PropAggregateProfile();
1091 module Case(){ ////toplevel
1096 // ledge (fixed keeper)
1097 Flip_rhs(1-keeper_side) intersection(){
1099 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1102 // outline of the whole case, to stop it protruding
1103 translate([0,0, -25])
1104 linear_extrude(height = 50)
1107 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1111 HingePortion(hex20, hex21) HingeBaseProfile();
1113 // buildout for prop recess
1114 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1115 linextr(case_bottom_z, epp2i[1])
1118 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1120 r = epp2o[0] - prcp2[0]);
1125 Flip_rhs(keeper_side)
1126 translate([0, -phone_cnr_rad, 0])
1128 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1131 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1132 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1136 RearCameraAperture();
1138 // struts (invisible, because they're buried in the case)
1139 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1144 if (!($button_leg_only && enable_support))
1146 translate([0,0,-10])
1147 linear_extrude(height= 20)
1148 ButtonPlan($button_l, 0,1);
1149 if ($button_leg_only)
1151 translate([phone_width/2, -400, kppe[1]])
1152 mirror([1-abs($rhsflip - keeper_side),0,0])
1153 cube([400, 800, 50]);
1154 if (enable_support && !$button_suppress_over_keeper)
1156 translate([-400, -400, kppd[1]])
1158 cube([800,800,100]);
1160 translate([0,0, -bppR[0]])
1161 linear_extrude(height= 20)
1162 ButtonPlan($button_l, 1,1);
1167 // apertures along top edge
1168 CaseAperture(jack_pos, jack_dia, 8);
1170 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1172 OrdinaryRearApertures();
1176 // gaps for the lid's hinge arms
1177 HingePortion(hex20 - hinge_x_arms_gap,
1178 hex21 + hinge_x_arms_gap)
1181 circle(r= hinge_r_arms_gap, $fn= 8);
1184 // screw holes in the hinge arms
1188 CatchPortion(epp4[1])
1193 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1194 rotate([0, ly_theta, 0])
1196 LanyardCutout(lanyard_channel_len);
1200 translate([prop_x_pos,0,0])
1203 linextr(-prop_recess_hw, +prop_recess_hw)
1205 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1206 circleat(prcp1 + 20*d,
1212 module LidAdhocMultiprintFrame(phase){
1213 if (led_window_style >= 3) {
1214 AdhocMultiprintFrame(phase, lpp13[1], -1);
1218 module LidAroundEdges(){
1219 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1223 module Lid(){ ////toplevel
1224 skew_centre = [0, lpp11[0], lpp11[1]];
1231 translate(skew_centre)
1232 multmatrix([[ 1, 0, 0, 0 ],
1233 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1236 translate(-skew_centre)
1238 LidEdgeFoldClearanceProfile();
1245 translate([0,0,-10])
1246 linear_extrude(height= 20)
1247 ButtonPlan($button_l, 1,0);
1250 translate([0,0,-100])
1251 linear_extrude(height= 200)
1252 ButtonCoverProfile();
1254 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1255 - lid_buttoncover_reinf))
1263 HingePortion(hex20, hex21) {
1268 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1270 // screw holes in the hinge arms
1274 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1277 linextr(-prop_recess_hw, +prop_recess_hw)
1279 for (pa = prop_angles)
1280 PropProfile(pa, 1,1);
1282 // notification led aperture
1283 if (led_window_style)
1284 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1285 translate([0,0,-10])
1286 cylinder(r=nla_r0, h=20);
1287 if (led_window_style >= 2)
1288 translate([0,0, -nla_t])
1289 cylinder(r=nla_r2, height=20);
1294 LidAdhocMultiprintFrame(1);
1297 module HingeLever(){ ////toplevel
1299 // outer body, positive
1300 HingePortion(hex22, hex22 + phone_width/2)
1301 HingeLeverOuterProfile();
1303 // space for the screws
1304 HingePortion(hex26, hex24)
1305 HingeLeverInnerProfile();
1307 // recesses for the nuts
1308 HingePortion(hex23, hex26+1)
1309 HingeLeverNutProfile();
1311 // bores for the screws
1314 // space for the charging cable
1316 Flip_hinge() MicroUSB();
1320 module LidWindow(){ ////toplevel
1321 translate([led_pos[0], -led_pos[1], lpp13[1]])
1323 cylinder(r= nla_r1, h=nla_t);
1324 LidAdhocMultiprintFrame(0);
1327 module LidWindowPrint(){ ////toplevel
1332 module DemoLidWindowSelect(){
1333 translate([led_pos[0], led_pos[1], -100]) {
1334 translate([0, -30, 0]) cube([400, 400, 200]);
1338 module DemoLidWindow(){ ////toplevel
1341 translate([0,40,0]){
1342 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1343 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1347 module HingeLeverPrint(){ ////toplevel
1349 translate([-phone_width/2, phone_height, 0])
1353 module TestSelectLength(){
1354 translate([-30, -200, -20])
1355 cube([30 + 15, 250, 40]);
1358 module TestLength(){ ////toplevel
1365 module TestLengthRight(){ ////toplevel
1373 module TestSelectWidth(){
1374 translate([-30, -(phone_height - 25), -20])
1376 cube([200, 50, 40]);
1379 module TestWidth(){ ////toplevel
1386 module TestLidWidthPrint(){ ////toplevel
1387 rotate([0,180.0]) intersection(){
1393 module TestSelectRearAperture(){
1396 translate([20, 0,0])
1397 cube([42, 2, 1], center=true);
1401 module TestSelectCamera(){
1403 TestSelectRearAperture()
1404 RearCameraAperture();
1405 cube([0.1, 50, 0.1]);
1409 module TestSelectOrdinaryRearApertures(){
1410 TestSelectRearAperture()
1411 OrdinaryRearApertures();
1414 module TestCamera(){ ////toplevel
1421 module TestLidByCamera(){ ////toplevel
1428 module TestLidByCameraPrint(){ ////toplevel
1429 rotate([180,0,0]) TestLidByCamera();
1432 module DemoByCamera(){ ////toplevel
1433 color("blue") TestLidByCamera();
1434 color("red") TestCamera();
1437 module OneKeeper(){ ////toplevel
1438 translate([0, -phone_cnr_rad, 0])
1440 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1444 module OneKeeperPrint(){ ////toplevel
1449 module LidPrint(){ ////toplevel
1454 module TestSelectFrame(){
1455 include = [1,-1] * (epp2i[0] + 4);
1458 cube(1000, center=true);
1459 translate([0,0, -100])
1460 linear_extrude(height=200)
1461 rectfromto(include, inside_br - include);
1465 module TestSelectLidFrame(){
1467 translate([led_pos[0], -led_pos[1], -50])
1468 cylinder(r= nla_r2+3, h=100);
1471 module TestFrameCase(){ ////toplevel
1477 TestSelectOrdinaryRearApertures();
1482 module TestSelectTopApertures(){
1483 translate([-100, -35, -100])
1484 cube([400, 100, 200]);
1485 LidAdhocMultiprintFrame(0);
1486 LidAdhocMultiprintFrame(1);
1489 module TestTopApertures(){ ////toplevel
1493 TestSelectTopApertures();
1497 module TestLidTopAperturesPrint(){ ////toplevel
1498 rotate([0,180,0]) intersection(){
1500 TestSelectLidFrame();
1501 TestSelectTopApertures();
1505 module TestLidWindowTopAperturesPrint(){ ////toplevel
1506 rotate([0,180,0]) intersection(){
1508 TestSelectTopApertures();
1512 module TestFrameLidPrint(){ ////toplevel
1513 rotate([0,180,0]) intersection(){
1515 TestSelectLidFrame();
1519 module ButtonPlanForDemo(z, deep, cut){
1521 ButtonPlan(8, deep, cut);
1524 module HingeScrews(){
1525 Flip_rhs() Flip_bot(1){
1526 for (c= [ hppT, hppB ])
1531 translate([0,0,-.2])
1532 cylinder( r= hingescrew_shaft_dia/2,
1533 h = hingescrew_shaft_len+0.2 );
1535 translate([0,0,+.1])
1536 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1541 module DemoPropAngleSelect(c){
1542 color(c) difference(){
1543 union(){ children(); }
1544 translate([ prop_x_pos, -400, -200 ])
1545 cube([ 400,800,400 ]);
1549 module DemoPropAngle(ang){
1550 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1551 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1559 DemoPropAngleSelect("red") Case();
1562 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1563 PropProfileAssignments(ang) {
1565 rotate([-$prp_theta, 0, 0])
1566 translate([0, $prpp1[0], -$prpp1[1]])
1572 translate([0,0, -hp_k*2])
1573 DemoPropAngleSelect("blue")
1577 module DemoPropAngles(){ ////toplevel
1578 for (i=[0 : len(prop_angles)-1])
1579 translate(i * [0, -100, 100])
1580 DemoPropAngle(prop_angles[i]);
1583 module DemoHingeAngle(ang1,ang2){
1584 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1585 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1596 color("blue") intersection(){
1599 translate([bppJ[0], -400, -200])
1601 cube([400, 800, 400]);
1602 translate([10, -400, -200])
1603 cube([10, 800, 400]);
1608 module DemoHingeAngles(){ ////toplevel
1609 angles = [ 0, 4, 8, 12 ];
1610 echo("angles",angles);
1611 for (i=[0 : len(angles)-1]) {
1612 translate(i * [0, 0, 30]) {
1613 DemoHingeAngle(0,angles[i]);
1614 translate([0, 200, 0])
1615 DemoHingeAngle(angles[i],0);
1620 module DemoSelectAdhocLeftRight(right=0) {
1621 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1622 mirror([1-right, 0,0])
1623 cube([400, 800, 200]);
1626 module DemoLeft(){ ////toplevel
1627 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1628 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1631 module DemoFrame(){ ////toplevel
1632 color("red") TestFrameCase();
1633 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1634 color("black") HingeScrews();
1638 module DemoLanyardCutout(){ ////toplevel
1642 module DemoHingedFrame(){ ///toplevel
1643 color("red") TestFrameCase();
1644 translate([0,0, -2*hp_k])
1645 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1648 color("orange") HingeLever();
1649 color("black") HingeScrews();
1653 module DemoHinge(){ ////toplevel
1654 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1656 translate([0,0, -hp_k*3])
1661 module DemoProfiles(){ ////toplevel
1665 translate([0,0,-1]) color("black") KeeperProfile(1);
1668 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1669 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1670 translate([0, ly_q_z]){
1671 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1672 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1676 translate([0,0,-5]) color("white") translate(epp2i)
1678 rectfromto([-15, 0],
1679 [+15, -max_case_bottom_edge_thickness]);
1682 LanyardMainChannelProfile();
1683 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1684 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1691 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1693 color("blue") ButtonCoverProfile();
1695 rectfromto(bppQ, demopoint_QR);
1696 rectfromto(bppR, demopoint_QR);
1700 translate([-20,0]) {
1701 color("black") ButtonPlanForDemo(-2, 0,1);
1702 color("red" ) ButtonPlanForDemo(-4, 1,1);
1703 color("blue") ButtonPlanForDemo(-6, 1,0);
1706 translate([0, -30]) {
1709 color("blue") HingeLidProfile();
1710 color("red") HingeBaseProfile();
1711 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1715 translate([-30, -60 + 30*f]) {
1716 translate([0,0,-4]) EdgeProfile();
1717 %translate([0,0,-10]) HingeBaseProfile();
1718 translate([0,-2] * f * hp_k) {
1719 translate([0,0,-4]) LidEdgeProfile();
1720 %translate([0,0,-10]) %HingeLidProfile();
1722 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1723 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1724 translate([0,0,0]) color("red") difference(){
1725 HingeLeverOuterProfile();
1726 HingeLeverInnerProfile();
1728 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1733 translate([20,-30]) {
1736 //translate([0,0,1]) CatchCutProfile();
1737 translate([0,0,+1]) color("red")
1738 difference(){ EdgeProfile(); CatchCutProfile(); }
1741 translate([40,-30]) {
1745 PropProfile(10, 1, 0);
1750 translate([60,-30]) {
1751 PropAggregateProfile();