// -*- C -*- // Hard case for Fairphone 2 // // Copyright 2018 Ian Jackson. There is NO WARRANTY. // See below for full licensing and disclaimer. // // Instructions // // 1. You will want to git clone this repository. // // 2. Decide about the notification LED aperture. See the variable // led_window_style, below. The default here is "ad-hoc // multi-colour", which can produces a translucent (clear-ish) // window set into the lid, even on a single-nozzle printer. // See "Ad-hoc multi-colour", below. // // 3. use "make" to generate the necessary files: // // make -j8 fairphone-case.auto.scads `for f in \ // HingePrint \ // LidWindowPrint \ // LidPrint \ // OneKeeperPrint \ // Case \ // ; do echo fairphone-case,$f.auto.stl; done` // // 4. Print them. Case and OneKeeperPrint should probably be // the same colour. // // For Lid and LidWindowPrint, if you are doing ad-hoc // multi-colour: // i. Set up for clear filament // ii. Print LidWindowPrint. Wait for it to finish. // It won't take long. As soon as it finishes, tell // your printer to warm up (so that in fact it does // not cool down). // iii. Leaving the output so far on the printbed, reload // your printer with the main lid colour. // iv. Print LidPrint. You can let this go unattended. // // 5. Assemble the hinge. You will need 4x M2 12mm machine screws // and 8x M2 full nuts. // // Make sure you get the hinge the right way round. If you're not // sure, run // openscad fairphone-case,DemoHinge.auto.scad // to see an assembly diagram. // // The nuts recess into the hinge. You will want very fine // pliers. As you screw each screw in, add the second nut when // the screw thread emerges from the first - this will be a // locknut. Screw each screw to an appropriate tightness for the // hinge stiffness. You want the lid-side hinge to be stiffer as // that makes closing the case work better. // // When you have the stiffness right, tighten the locknuts onto // each first nut. // // 6. In use: // // - To put the phone in, drop its RH side into the RH side of // the case. Then feed the keeper through the small hole. // Feed it right through. // // - The optional prop can be used to prop the phone up (in // portrait orientation only right now). See // openscad fairphone-case,DemoPropAngles.auto.scad // // Ad-hoc multi-colour // // This file is set up to let you make a translucent window using a // single-extruder printer, using a "two print run" technique. This // works well with our Lulzbot TAZ 5 and Aleph Objects' version of // Cura. If you are using a different printer, you may need to // adjust the parameters or try a different technique. In particular, // initial_layer_thick // set so that the window is one layer thick // initial_layer_width // set so that the slicer draws a rectangle around the whole // object, rather than putting a "skirt" or anything inside // // If you have a dual-extruder printer, you can set led_window_style // to 2 and do a single print of LidPrint and LidWindowPrint. // // Alternatively you can set it to 1 (just a hole) or 0 (no hole). // // Thanks to Clare Boothby for the ad-hoc multi-colour technique (and // the parameters for our Lulzbot TAZ 5 and Aleph Objects's Cura). // // Other phones // // It might well be possible to adapt this file for other phones. // If you do, let me know how you get on. // // // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY // // Copyright (C)2018 Ian Jackson. // // This program for generating a 3D model is free software: you can // redistribute it and/or modify it under the terms of the GNU // General Public License as published by the Free Software // Foundation, either version 3 of the License, or (at your option) // any later version. // // This program is distributed in the hope that it will be useful, // but WITHOUT ANY WARRANTY; without even the implied warranty of // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the // GNU General Public License for more details. // // You should have received a copy of the GNU General Public // License along with this program. If not, see // . // // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY // PROTECT YOUR PHONE ! It is your responsibility to decide whether // this case will meet your needs. include phone = [ 75.0, 145.0 ]; prop_buildout_less = 3; prop_angles = [ 15, 30, 45, 60 ]; bumper = [ 0.250, -0.025 ]; // ^ One side. Overall size is increased by twice this. // If no bumpers, is the gap around the phone. enable_support = 1; led_window_style = 3; // 0: no window // 1: simply an opening // 2: opening with separate cover model, for printing in clear (two colour) // 3: like 2 but one-layer window for ad-hoc multi-colour initial_layer_thick = 0.400; // ^ needed for mode 3 only initial_layer_width = 0.750; // ^ needed for mode 3 only multicolour_gap = 0.15; // each side phone_cnr_rad = 6.0; phone_rim_depth = 0.80; // includes allowance for a screen protector button_cutout_depth = 9; phone_edge_thick = 9.0; phone_total_thick = 12.0; phone_backside_slope_inner = 1.5; // larger means shallower phone_backside_slope_outer = 1.0; // larger means shallower camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back jack_pos = [ 13.83, 8.485 ]; jack_dia = 10.64 + .5; // some jack I had lying around led_pos = [ 13.98, 10.00 ]; led_aperture = 9; led_window_ledge = 0.75; // each side noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs noisecancelmic_dia = 4.00; //fingerpushhole_dias = [ 15, 18 ]; fingerpushhole_dias = []; rearspeaker_pos_bl = [ 12.64, 18.72 ]; rearspeaker_size = [ 3.76, 7.36 ]; microusb_above = 3.27 - 0.25; microusb_below = 0.0; microusb_width = 16.12 + 1.25; case_th_bottom = 2.5; case_th_lid = 3.0; case_th_side = 2.3; case_th_lip = 1.2; lid_screen_gap_extra = .66; case_struts_count = 6; case_struts_solid_below = 1.00; case_struts_solid_above = 0.75; case_struts_width = 0.10; keeper_th_z = 0.75; keeper_th_x = 0.75; keeper_inner_width = 2.75; keeper_inner_height = 2.75; keeper_slant_slope = 2; // larger means steeper keeper_gap_z_top = 0.25; keeper_gap_z_bot = 0.75; keeper_gap_x = 0.25; keeper_gap_x_holes = 0.75; keeper_side = 0; // 0 = lhs; 1 = rhs case_lip = 1.25; lid_gap_x = 0.25; lid_gap_z = 0.25; lid_lip = 1.75; lid_edgepart_width = 5.0; lid_buttoncover_thick = 1.3; catch_slop = 0.50; foldover_gap = 0.50; foldover_lever_gap = 0.50; // properties of the hinge fasteners hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw hingescrew_shaft_len = 12; hingescrew_fasteners_extra_thick = 0.40; // ^ amount of thread protruding if everything was completely nominal // and we are using two nuts hingescrew_nut_access_dia = 4.72 + 0.50; // ^ washer is 4.72 dia // also, want to get pliers or tiny spanner in to do up locknut hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop hingescrew_nut_thick = 1.93; hingescrew_head_th = 1.38 + 0.75; hingescrew_head_dia = 3.92; hingescrew_nut_recess_portion = 2/3; // portion of nut in recess lever_cover_th = 0.75; hingemount_th = 2.5; hingemount_wd = 4.8725; $fa = 5; $fs = 0.1; button_l_fudge = 4.4; buttonishleg_default_l_is_fudge = 10; hinge_base_slope = 1.5; // bigger is steeper strut_min_at_end = 1.5; hinge_x_gap = 0.125; hinge_x_postscrew_gap = 0.75; hinge_x_arms_gap = 0.35; hinge_r_arms_gap = 0.55; rearspeaker_gap = [ 2.0, 2.0 ]; // each side catch_len = 7.5; catch_width = 15; catch_thickness = 1.0; catch_side_gap = 0.75; // each side catch_depth = 0.75; catch_height = 0.35; catch_finger_height = 1.5; catch_finger_depth = 2.5; catch_topcurve_r = 5.0; prop_recess_under = 0.50; prop_recess_slop = 0.200; // each side prop_end_dia = 0.5; prop_main_th = 3; prop_taper_len = 6; prop_main_width = 4; prop_side_gap = 0.75; // each side prop_lidrecess_behind = 0.75; prop_caserecess_behind = 0.75; prop_caserecess_taper = 0.45; // one side only prop_prop_gap = 0.5; prop_prong_heel_slope = 0.5; lid_fold_clearance_antislop = 0.5; // ---------- calculated ---------- phone_width = (phone + bumper*2)[0]; phone_height = (phone + bumper*2)[1]; inside_br = [phone_width, -phone_height]; prop_prong_h = prop_main_th; //echo(camera_pos_tl + bumper, // camera_pos_br + bumper); // ----- could be changed ----- lid_buttoncover_gap = lid_gap_x; lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top; phone_backside_slope_thick = phone_total_thick - phone_edge_thick; //prop_lidrecess_depth = case_th_lid - prop_recess_under; //prop_nose_len = case_th_lid - prop_recess_under; //prop_recess_slope = tan(prop_max_angle); // bigger means steeper //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap; //lid_lip_overlap_width xxx bad name = ; //lid_lip_inner_slope = [ 5, 5 ]; // xxx epp0 = [0,0]; epp1 = [0, -phone_edge_thick]; epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ]; epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ]; epp3 = epp2i + [10, 0]; epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip); epp4 = epp5 + [-1,0] * case_th_side; kppe = [0,0]; kppd = kppe + [1,0] * keeper_inner_width; kppc = kppd + [0,1] * keeper_th_z; kppb = [ kppe[0] - keeper_th_x, kppc[1] ]; kppf = kppe - [0,1] * keeper_inner_height; kppa = [ kppb[0], kppf[1] ]; lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ]; lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ]; lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width); // exact x posn not very important; must extend past end of keeper lpp15 = [ lpp14[0], epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid + lid_screen_gap_extra ]; // ^ beam theory says to maximise force before contact, // the gap below the `beam' (the lid) must be 1/3 // the thickness (ie the lid thickness) if the beam // is solid, or 1/2 if it has a top and bottom only. // ours is mostly solid. lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]), case_th_lip); lpp12 = [ epp4[0] + lp_r12, lpp11[1] ]; lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ]; case_bottom_z = epp2o[1] - case_th_bottom; // button profile bppM = epp4 + [0,5]; bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ]; bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ]; bppS = [ epp1[0], bppR[1] ]; bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ]; bppP = bppQ + [0,1] * lid_buttoncover_gap; bppO = [ bppN[0], bppP[1] ]; bppL = lpp10 + [5,0]; bppK = [ bppL[0], bppN[1] ]; bppJ = [ bppN[0], bppL[1] ]; bppU = [ bppJ[0], lpp12[1] ]; bppV = lpp11; bppW = lpp10; echo("BUTTON COVER TH", bppO[0] - bppP[0]); // notification led aperture nla_r0 = led_aperture/2; nla_r1 = nla_r0 + led_window_ledge; nla_r2 = nla_r1 + multicolour_gap; nla_t = led_window_style >= 3 ? initial_layer_thick : led_window_style >= 2 ? led_window_ledge : 0; // hinge plan hp_rn = hingescrew_nut_access_dia/2; hp_r2_min = hp_rn + lever_cover_th; hp_rs = hingescrew_shaft_dia/2; hp_r1_min = hp_rs + hingemount_th; hp_r1 = max(hp_r1_min, hp_r2_min); hp_r2 = hp_r1; hppU = lpp13; hppS = epp2o + [0,-1] * case_th_bottom; hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap); hppM = [ epp4[0] - foldover_lever_gap - hp_r2, 0.5 * (hppU + hppS)[1] ]; hppT = [ hppM[0], hppU[1] - hp_r1 ]; hppB = hppT + [0,-1] * hp_k; hppE_y = epp2o[1] - case_th_bottom + hp_r1; hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope; hppE = [ hppE_x, hppE_y ]; // hinge elevation x coords hex20 = max(epp2o[0], phone_cnr_rad, kppd[0] + hingescrew_head_th + keeper_gap_x_holes); hex21 = hex20 + hingemount_wd; hex22 = hex21 + hinge_x_gap; hex27 = hex20 + hingescrew_shaft_len; hex24 = hex27 + hinge_x_postscrew_gap; hex23 = hex27 - (hingescrew_nut_thick*2 + hingescrew_fasteners_extra_thick); hex26 = hex23 + hingescrew_nut_thick * 2/3; echo(hex20, hex21, hex22, hex23, hex24); // 6, 10.8725, 10.9975, 13.74, 18.75 module chk(act,exp) { if (abs(act-exp) > 1e-9) echo("WRONG", act, exp); else echo("ok", act); } chk(hex20, 6); chk(hex21, 10.8725); chk(hex22, 10.9975); chk(hex23, 13.74); chk(hex24, 18.75); lid_fold_clearance_skew = (lpp10[1] - hppB[1]) / (lpp10[0] - hppB[0]); echo("SK",lid_fold_clearance_skew); // catch cppJ = [ epp4[0] + catch_thickness, lpp10[1] ]; cppA = cppJ + [lid_gap_x, -lid_gap_z]; cppB = [ epp0[0], cppA[1] ]; cppP = [ epp4[0], cppJ[1] ]; cppS = cppJ + [0,-1] * catch_len; cppD = [ cppA[0], cppS[1] + catch_slop ]; cppC = [ cppB[0], cppD[1] ]; cppT = cppS + [1,0] * catch_depth; cppU = cppT + [0,-1] * catch_height; cppV = [ cppS[0], cppU[1] - catch_depth ]; cppR = 0.5*(cppP + cppJ); cp_rQ = 0.5 * (cppJ[0] - cppP[0]); cppQ = [ cppR[0], cppV[1] - (catch_finger_height - cp_rQ) ]; cppF = [ cppV[0] + catch_finger_depth, cppC[1] ]; // prop recess in case prop_x_pos = phone_width/2; prop_recess_hw = 0.5 * prop_main_width + prop_side_gap; prc_r1 = prop_end_dia/2; prc_r3 = prc_r1 + prop_recess_slop; prcp2 = [ epp4[0] + prop_buildout_less, case_bottom_z ]; prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0]; prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind, epp2i[1] - prc_r3 - prop_recess_under]; // prop recess in lid prl_r10 = prop_end_dia/2; prl_r10o = prl_r10 + prop_recess_slop; prlp10 = lpp10 + [1,1] * prl_r10o + [1,0] * prop_lidrecess_behind + [0,1] * prop_recess_under; // prop $prpp10 = [0,0]; $prpp11 = [0, prop_taper_len]; $prp_r10 = prl_r10; // ---------- modules ---------- module AdhocMultiprintFrame(phase, z0, zs) { // from z0 to z0 + zs*layer extra = phase * (initial_layer_width + multicolour_gap) + 5; xextra = extra + -epp4[0]; xrange = [ 0, phone_width ] + [-1,+1] * xextra; yextra = extra + -epp4[0]; yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra; p0 = [ xrange[0], yrange[0] ]; p1 = [ xrange[1], yrange[1] ]; echo(p0, p1); translate([0,0, z0]) mirror([0,0, zs<0 ? 1 : 0]) linear_extrude(height= initial_layer_thick) difference(){ rectfromto(p0 - [1,1] * initial_layer_width, p1 + [1,1] * initial_layer_width); rectfromto(p0, p1); } } module KeeperProfile(slant=0){ use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope; polygon([use_e, kppd, kppc, kppb, kppa, kppf]); } module EdgeProfile(){ difference(){ hull(){ translate(epp3) square(case_th_bottom*2, center=true); circleat(epp2o, r=case_th_bottom); circleat(epp1, r=case_th_side); rectfromto(epp0, epp4); } polygon([ epp5 + [0,10], epp1, epp2i, epp3 + [10,0] ]); } } module LidEdgeProfile(){ polygon([ lpp10, lpp11, lpp12, lpp13, lpp13 + [10, 0], lpp15 + [10, 0], lpp15, lpp14, ]); intersection(){ circleat(lpp12, r=lp_r12); rectfromto( lpp12 + [-10, 0], lpp12 + [+10, +10] ); } } module LidEdgeFoldClearanceProfile(){ translate([-lid_fold_clearance_antislop, 0]) polygon([ lpp10, lpp11, lpp11 + [-20, 0], lpp11 + [-20, 20], lpp11 + [+20, 20], lpp10 + [+20, 0] ]); } module ButtonCoverProfile(){ intersection(){ polygon(concat([ bppM, bppP, bppO, bppJ ], (enable_support && !$button_suppress_over_keeper ? [ bppU, bppV, bppW ] : []), [ bppL, bppK ])); hull(){ EdgeProfile(); LidEdgeProfile(); } } } module ButtonPlan(l, deep, cut){ epsilon = (cut ? 0 : lid_buttoncover_gap); delta = (deep ? lid_buttoncover_overlap : 0); C = [0,0]; // by definition T = [ 0, epp4[1] ]; G = T + [0,10]; B0 = C + [0,-1] * button_cutout_depth; B1 = B0 + [0,1] * epsilon; r0 = 0.5 * (T[1] - B0[1]); A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ]; H = A + [0,-1] * delta; D = A + [-2,0] * r0; F = D + [0,10]; E0 = 0.5 * (D + A); E1 = E0 + [1,0] * epsilon; I0 = [ E0[0], H[1] ]; I1 = [ E1[0], H[1] ]; hull(){ for (m=[0,1]) mirror([m,0]) circleat(H, r0 - epsilon); } for (m=[0,1]) mirror([m,0]) { difference(){ polygon([ E1, I1, H, B1, G, F, D ]); circleat(D, r0 + epsilon); } } } module CatchCatchProfile(){ hull(){ for (c=[ cppR, cppQ ]) circleat(c, cp_rQ); } hull(){ circleat(lpp12, lp_r12); circleat(lpp12 + [5,0], lp_r12); rectfromto(cppP, cppP + [5,0.1]); } polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]); } module CatchCutProfile(){ polygon([ cppB, cppA, cppD, cppF, cppF + [0,-10], cppF + [-10,-10], lpp12 + [-10,0], lpp12 + [10,0] ]); } module Flip_rhs(yn=[0,1]) { for ($rhsflip=yn) { translate([phone_width/2, 0, 0]) mirror([$rhsflip,0,0]) translate([-phone_width/2, 0, 0]) children(); } } module Flip_bot(yn=[0,1]) { for ($botflip=yn) { translate([0, -phone_height/2, 0]) mirror([0, $botflip, 0]) translate([0, phone_height/2, 0]) children(); } } module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ // sides Flip_rhs(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) children(0); } // corners Flip_rhs() Flip_bot() { translate([+1,-1] * phone_cnr_rad) intersection(){ rotate_extrude() intersection(){ mirror([1,0,0]) translate([-1,0] * phone_cnr_rad) children(0); rectfromto([0,-20],[10,20]); } translate([-10, 0, -20] + 0.01 * [+1,-1, 0] ) cube([10,10,40]); } } // top and bottom Flip_bot(){ translate([ phone_width - phone_cnr_rad, 0,0 ]) rotate([90,0,-90]) linear_extrude(height = phone_width - phone_cnr_rad*2) children(0); } // fill translate([0,0, fill_zstart]) mirror([0,0, fill_downwards]) linear_extrude(height = fill_th) rectfromto([+1,-1] * phone_cnr_rad, [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad); } module CaseAperture(pos, dia, $fn) { theta = 180/$fn; translate([ pos[0] + bumper[0], -epp2i[0], -pos[1] ]) rotate([-90, theta, 0]) cylinder(r = dia/2 / cos(theta), h = 60); } module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){ // y_ref_sign: // +1 measured from top of actual phone to top of button // -1 measured from bottom of actual phone to bottom of button // 0 y is centre of button in coordinate system $button_l= l; $button_suppress_over_keeper= suppress_over_keeper; eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 : y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 : y; //echo(eff_y); translate([0, eff_y, 0]) children(); } module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { $button_leg_only = true; SideButton(y, y_ref_sign, l) children(); } module Buttons(){ Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume Flip_rhs( ) LidButtonishLeg(14, -1) children(); // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); } module Struts(x_start, z_min, th){ // if th is negative, starts at z_min and works towards -ve z // and object should then be printed other way up for (i= [1 : 1 : case_struts_count]) { translate([0, 0, z_min]) mirror([0,0, th<0 ? 1 : 0]) translate([0, -phone_height * i / (case_struts_count+1), case_struts_solid_below]) linear_extrude(height= abs(th) -(case_struts_solid_below+case_struts_solid_above)) rectfromto([ x_start, -0.5 * case_struts_width ], [ phone_width - x_start, +0.5 * case_struts_width ]); } } module OrdinaryRearAperture(rhs,bot, pos){ Flip_rhs(rhs) Flip_bot(bot) linextr(-20, 20) mirror([0,1]) translate(pos + bumper) children(); } module MicroUSB(){ Flip_bot(1){ rotate([90,0,0]) mirror([0,0,1]) linextr(-epp2i[0], 60) translate([0.5 * phone_width, 0, 0]) rectfromto([-microusb_width/2, epp2i[1] + microusb_below], [+microusb_width/2, epp0[1] + -microusb_above]); } } module OrdinaryRearApertures(){ // rear speaker OrdinaryRearAperture(1,1, rearspeaker_pos_bl) rectfromto(-rearspeaker_gap, rearspeaker_size + rearspeaker_gap); // finger hole to remove phone if (len(fingerpushhole_dias)) OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0], phone[1]/2 ]) scale(fingerpushhole_dias) circle(r= 0.5 ); } module RearCameraAperture(){ Flip_rhs(1) mirror([0, 0, 1]) linear_extrude(height = 20) mirror([0, 1, 0]) translate(bumper) rectfromto(camera_pos_tl, camera_pos_br); } module HingeLidProfile(){ hull(){ circleat(hppT, hp_r1); circleat(lpp12, lp_r12); polygon([lpp10, lpp13 + [2,0], lpp12, hppT]); } } module HingeBaseProfile(){ difference(){ hull(){ circleat(hppB, hp_r1); circleat(hppE, hp_r1); circleat(epp2o, case_th_bottom); circleat(hppB + [10,0], hp_r1); } polygon([epp5, epp1, epp2i, epp3, bppL]); } } module HingeLeverOuterProfile(){ hull(){ circleat(hppT, hp_r2); circleat(hppB, hp_r2); } } module HingeLeverInnerProfile(){ for (s = [-1,+1]) { c = s > 0 ? hppT : hppB; translate(c) mirror([0,0,s>0]) rotate(s<0 ? -40 : 0) hull() for (x=[-20,20]) for (y=[0, s * 10]) translate([x,y]) circle(hp_rn); } } module HingeLeverNutProfile(){ for (c= [hppB, hppT]) { translate(c) circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30)); } } module Flip_hinge(doflip=1){ hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]]; translate(hinge_origin) rotate([doflip*180,0,0]) translate(-hinge_origin) children(); } module HingePortion(x0,x1){ Flip_rhs() Flip_bot(1) translate([x0,0,0]) mirror([1,0,0]) rotate([90,0,-90]) linear_extrude(height=x1-x0) children(); } module CatchPortion(xwidth, ztop){ width = catch_width + xwidth; w = width + catch_topcurve_r*2 + 1; translate([phone_width/2, 0,0]){ difference(){ rotate([90,0,-90]) linextr(-w/2, w/2) children(0); translate([0, 50, 0]) rotate([90,0,0]) linear_extrude(height=100){ for (m=[0,1]) mirror([m,0,0]) { hull(){ translate([w/2, ztop - catch_topcurve_r]) circle(catch_topcurve_r); translate([w/2, -50]) square(catch_topcurve_r*2, center=true); } } } } } } module CaseBase(){ AroundEdges(epp3[1], case_th_bottom, 1) EdgeProfile(); } function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0]; module PropProfileAssignments(gamma){ // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS) x = prop_x(gamma); p = phone_height + prlp10[0] - hppB[0]; b = p + x; q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition a = q + x; c = sqrt(a*a + b*b - 2*a*b*cos(gamma)); $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) ); $prp_theta = 90 - $prp_alpha; beta = 180 - $prp_alpha - gamma; psi = 90 - beta; //echo("abc", a,b,c); v1 = [ [ cos(psi), -sin(psi) ], // x [ sin(psi), cos(psi) ] ]; // y $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ]; $prp_r1 = prc_r1; $prp_r11 = prop_main_th/2; $prpp1 = $prpp7 + [1,0] * // this is approximate, but will do (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]); $prpp3 = $prpp1 + v1[0] * -$prp_r1 + v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap); $prpp12 = $prpp3 + v1[0] * (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1])); $prp_r8 = prop_main_th; $prpp4 = [ prop_main_th/2, $prpp3[1] ]; $prp_r5 = $prp_r8; $prpp5 = [ $prpp12[0] - $prp_r5, $prpp3[1] - prop_prong_h + $prp_r5 ]; $prpp6 = $prpp4 + [0,-1] * (prop_prong_h + prop_prong_heel_slope * ($prpp5[0] - $prpp4[0])); $prpp8 = $prpp4 + [0,-1] * $prp_r8; $prpp9 = $prpp8 + [-1,0] * $prp_r8; children(); } module PropProfile(gamma, cut=0, rot=0){ ////toplevel PropProfileAssignments(gamma){ //#circleat($prpp3,1); //#circleat($prpp12,1); if (!cut) { hull(){ translate($prpp8) intersection(){ circle($prp_r8); polygon([[-20,-0], [20,20], [0,0]]); } rectfromto($prpp6, $prpp9); translate($prpp5) intersection(){ circle($prp_r5); polygon([[-10,-10], [0,0], [10,0]]); } rectfromto($prpp12 + [0,-0.1], $prpp3); } hull(){ circleat($prpp1, $prp_r1); rectfromto($prpp12 + [0,-0.1], $prpp3); } } // main shaft rotate([0,0, rot*-$prp_theta]){ hull(){ extra = cut ? prop_recess_slop : 0; rectfromto($prpp6, $prpp9); circleat($prpp11, $prp_r11 + extra); circleat($prpp10, $prp_r10 + extra); } } } } module PropAggregateProfile(){ for (angle = prop_angles) PropProfile(angle, 0,0); } module Prop(){ ////toplevel hw = prop_main_width/2; linextr(-hw, +hw) PropAggregateProfile(); } module Case(){ ////toplevel difference(){ union(){ CaseBase(); // ledge (fixed keeper) Flip_rhs(1-keeper_side) intersection(){ rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) KeeperProfile(1); // outline of the whole case, to stop it protruding translate([0,0, -25]) linear_extrude(height = 50) hull() Flip_bot() circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); } // hinge HingePortion(hex20, hex21) HingeBaseProfile(); // buildout for prop recess if (prop_caserecess_buildout_r > 0) Flip_rhs(1) linextr(case_bottom_z, epp2i[1]) hull() { for (dxs = [-1,+1]) circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r, -epp2o[0] ], r = epp2o[0] - prcp2[0]); } } // slot for keeper Flip_rhs(keeper_side) translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) minkowski(){ KeeperProfile(); rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ], [ keeper_gap_x_holes, +keeper_gap_z_top ]); } // front camera RearCameraAperture(); // struts (invisible, because they're buried in the case) Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom); Buttons(){ mirror([1,0,0]) rotate([90,0,90]) { if (!($button_leg_only && enable_support)) intersection(){ translate([0,0,-10]) linear_extrude(height= 20) ButtonPlan($button_l, 0,1); if ($button_leg_only) rotate([-90,90,0]) translate([phone_width/2, -400, kppe[1]]) mirror([1-abs($rhsflip - keeper_side),0,0]) cube([400, 800, 50]); if (enable_support && !$button_suppress_over_keeper) rotate([-90,90,0]) translate([-400, -400, kppd[1]]) mirror([0,0,1]) cube([800,800,100]); } translate([0,0, -bppR[0]]) linear_extrude(height= 20) ButtonPlan($button_l, 1,1); } } // apertures along top edge CaseAperture(jack_pos, jack_dia, 8); Flip_rhs(1) CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8); OrdinaryRearApertures(); MicroUSB(); // gaps for the lid's hinge arms HingePortion(hex20 - hinge_x_arms_gap, hex21 + hinge_x_arms_gap) minkowski(){ HingeLidProfile(); circle(r= hinge_r_arms_gap, $fn= 8); } // screw holes in the hinge arms HingeScrews(); // catch striker CatchPortion(catch_side_gap*2, epp4[1]) CatchCutProfile(); // prop recess Flip_rhs(1) translate([prop_x_pos,0,0]) mirror([0,1,0]) rotate([90,0,90]) linextr(-prop_recess_hw, +prop_recess_hw) hull(){ for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ]) circleat(prcp1 + 20*d, prc_r3); } } } module LidAdhocMultiprintFrame(phase){ if (led_window_style >= 3) { AdhocMultiprintFrame(phase, lpp13[1], -1); } } module LidAroundEdges(){ AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0) children(); } module Lid(){ ////toplevel skew_centre = [0, lpp11[0], lpp11[1]]; difference(){ union(){ intersection(){ LidAroundEdges() LidEdgeProfile(); translate(skew_centre) multmatrix([[ 1, 0, 0, 0 ], [ 0, 1, -lid_fold_clearance_skew, 0 ], [ 0, 0, 1, 0 ], [ 0, 0, 0, 1 ]]) translate(-skew_centre) LidAroundEdges() LidEdgeFoldClearanceProfile(); } // button covers Buttons(){ intersection(){ rotate([90,0,90]) translate([0,0,-10]) linear_extrude(height= 20) ButtonPlan($button_l, 1,0); rotate([90,0,0]) translate([0,0,-100]) linear_extrude(height= 200) ButtonCoverProfile(); } } // hinge arms HingePortion(hex20, hex21) { LidEdgeProfile(); HingeLidProfile(); } // catch CatchPortion(0, lpp12[1]) CatchCatchProfile(); } Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid); // screw holes in the hinge arms HingeScrews(); // prop recess translate([prop_x_pos, -prlp10[0], prlp10[1]]) mirror([0,1,0]) rotate([90,0,90]) linextr(-prop_recess_hw, +prop_recess_hw) hull() for (pa = prop_angles) PropProfile(pa, 1,1); // notification led aperture if (led_window_style) translate([led_pos[0], -led_pos[1], lpp13[1]]) { translate([0,0,-10]) cylinder(r=nla_r0, h=20); if (led_window_style >= 2) translate([0,0, -nla_t]) cylinder(r=nla_r2, height=20); } } LidAdhocMultiprintFrame(1); } module HingeLever(){ ////toplevel difference() { // outer body, positive HingePortion(hex22, hex22 + phone_width/2) HingeLeverOuterProfile(); // space for the screws HingePortion(hex26, hex24) HingeLeverInnerProfile(); // recesses for the nuts HingePortion(hex23, hex26+1) HingeLeverNutProfile(); // bores for the screws HingeScrews(); // space for the charging cable MicroUSB(); Flip_hinge() MicroUSB(); } } module LidWindow(){ ////toplevel translate([led_pos[0], -led_pos[1], lpp13[1]]) mirror([0,0,1]) cylinder(r= nla_r1, h=nla_t); LidAdhocMultiprintFrame(0); } module LidWindowPrint(){ ////toplevel rotate([0,180,0]) LidWindow(); } module DemoLidWindowSelect(){ translate([led_pos[0], led_pos[1], -100]) { translate([0, -30, 0]) cube([400, 400, 200]); } } module DemoLidWindow(){ ////toplevel %Lid(); LidWindow(); translate([0,40,0]){ color("blue") intersection(){ Lid(); DemoLidWindowSelect(); } color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); } } } module HingeLeverPrint(){ ////toplevel rotate([-90,0,0]) translate([-phone_width/2, phone_height, 0]) HingeLever(); } module TestSelectLength(){ translate([-30, -200, -20]) cube([30 + 15, 250, 40]); } module TestLength(){ ////toplevel intersection(){ Case(); TestSelectLength(); } } module TestLengthRight(){ ////toplevel intersection(){ Case(); Flip_rhs(1) TestSelectLength(); } } module TestSelectWidth(){ translate([-30, -(phone_height - 25), -20]) mirror([0, 1, 0]) cube([200, 50, 40]); } module TestWidth(){ ////toplevel intersection(){ Case(); TestSelectWidth(); } } module TestLidWidthPrint(){ ////toplevel rotate([0,180.0]) intersection(){ Lid(); TestSelectWidth(); } } module TestSelectRearAperture(){ minkowski(){ union() children(); translate([20, 0,0]) cube([42, 2, 1], center=true); } } module TestSelectCamera(){ minkowski(){ TestSelectRearAperture() RearCameraAperture(); cube([0.1, 50, 0.1]); } } module TestSelectOrdinaryRearApertures(){ TestSelectRearAperture() OrdinaryRearApertures(); } module TestCamera(){ ////toplevel intersection(){ Case(); TestSelectCamera(); } } module TestLidByCamera(){ ////toplevel intersection(){ Lid(); TestSelectCamera(); } } module TestLidByCameraPrint(){ ////toplevel rotate([180,0,0]) TestLidByCamera(); } module DemoByCamera(){ ////toplevel color("blue") TestLidByCamera(); color("red") TestCamera(); } module OneKeeper(){ ////toplevel translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height - phone_cnr_rad * 2) KeeperProfile(); } module OneKeeperPrint(){ ////toplevel rotate([0,180,0]) OneKeeper(); } module LidPrint(){ ////toplevel rotate([0,180,0]) Lid(); } module TestSelectFrame(){ include = [1,-1] * (epp2i[0] + 4); difference(){ cube(1000, center=true); translate([0,0, -100]) linear_extrude(height=200) rectfromto(include, inside_br - include); } } module TestSelectLidFrame(){ TestSelectFrame(); translate([led_pos[0], -led_pos[1], -50]) cylinder(r= nla_r2+3, h=100); } module TestFrameCase(){ ////toplevel intersection(){ Case(); union(){ TestSelectFrame(); TestSelectCamera(); TestSelectOrdinaryRearApertures(); } } } module TestSelectTopApertures(){ translate([-100, -35, -100]) cube([400, 100, 200]); LidAdhocMultiprintFrame(0); LidAdhocMultiprintFrame(1); } module TestTopApertures(){ ////toplevel intersection(){ Case(); TestSelectFrame(); TestSelectTopApertures(); } } module TestLidTopAperturesPrint(){ ////toplevel rotate([0,180,0]) intersection(){ Lid(); TestSelectLidFrame(); TestSelectTopApertures(); } } module TestLidWindowTopAperturesPrint(){ ////toplevel rotate([0,180,0]) intersection(){ LidWindow(); TestSelectTopApertures(); } } module TestFrameLidPrint(){ ////toplevel rotate([0,180,0]) intersection(){ Lid(); TestSelectLidFrame(); } } module ButtonPlanForDemo(z, deep, cut){ translate([0,0,z]) ButtonPlan(8, deep, cut); } module HingeScrews(){ Flip_rhs() Flip_bot(1){ for (c= [ hppT, hppB ]) translate([ hex20, -c[0], c[1] ]){ rotate([0,90,0]) translate([0,0,-.2]) cylinder( r= hingescrew_shaft_dia/2, h = hingescrew_shaft_len+0.2 ); rotate([0,-90,0]) translate([0,0,+.1]) cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th ); } } } module DemoPropAngleSelect(c){ color(c) difference(){ union(){ children(); } translate([ prop_x_pos, -400, -200 ]) cube([ 400,800,400 ]); } } module DemoPropAngle(ang){ hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2]; hC = [0, -(phone_height - hppB[0]), hppB[1]]; translate(hL) rotate([ang/2,0,0]) translate(-hL) translate(hC) rotate([ang/2,0,0]) translate(-hC) { DemoPropAngleSelect("red") Case(); color("orange") translate([prop_x_pos, -prcp1[0], prcp1[1]]) PropProfileAssignments(ang) { echo($prpp1); rotate([-$prp_theta, 0, 0]) translate([0, $prpp1[0], -$prpp1[1]]) rotate([90,0,-90]) Prop(); } } translate([0,0, -hp_k*2]) DemoPropAngleSelect("blue") Lid(); } module DemoPropAngles(){ ////toplevel for (i=[0 : len(prop_angles)-1]) translate(i * [0, -100, 100]) DemoPropAngle(prop_angles[i]); } module DemoHingeAngle(ang1,ang2){ hL = [0, -(phone_height - hppT[0]), hppT[1]]; hC = [0, -(phone_height - hppB[0]), hppB[1]]; translate(hL) rotate([ang2,0,0]) translate(-hL) translate(hC) rotate([ang1,0,0]) translate(-hC) { color("red") Lid(); } color("blue") intersection(){ Case(); union(){ translate([bppJ[0], -400, -200]) mirror([1,0,0]) cube([400, 800, 400]); translate([10, -400, -200]) cube([10, 800, 400]); } } } module DemoHingeAngles(){ ////toplevel angles = [ 0, 4, 8, 12 ]; echo("angles",angles); for (i=[0 : len(angles)-1]) { translate(i * [0, 0, 30]) { DemoHingeAngle(0,angles[i]); translate([0, 200, 0]) DemoHingeAngle(angles[i],0); } } } module DemoSelectAdhocLeftRight(right=0) { translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section mirror([1-right, 0,0]) cube([400, 800, 200]); } module DemoLeft(){ ////toplevel color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); } color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); } } module DemoFrame(){ ////toplevel color("red") TestFrameCase(); color("blue") intersection(){ Lid(); TestSelectLidFrame(); } color("black") HingeScrews(); %HingeLever(); } module DemoHingedFrame(){ ///toplevel color("red") TestFrameCase(); translate([0,0, -2*hp_k]) color("blue") intersection(){ Lid(); TestSelectLidFrame(); } Flip_hinge(){ color("orange") HingeLever(); color("black") HingeScrews(); } } module DemoHinge(){ ////toplevel translate([ -0.5*phone_width, phone_height, hp_k*3 ]) { DemoFrame(); translate([0,0, -hp_k*3]) DemoHingedFrame(); } } module DemoProfiles(){ ////toplevel LidEdgeProfile(); %EdgeProfile(); KeeperProfile(); translate([0,0,-1]) color("black") KeeperProfile(1); translate([20,0]) { LidEdgeProfile(); %EdgeProfile(); demopoint_QR = [ bppS[0], bppQ[1] - 0.1]; color("blue") ButtonCoverProfile(); color("red") { rectfromto(bppQ, demopoint_QR); rectfromto(bppR, demopoint_QR); } } translate([-20,0]) { color("black") ButtonPlanForDemo(-2, 0,1); color("red" ) ButtonPlanForDemo(-4, 1,1); color("blue") ButtonPlanForDemo(-6, 1,0); } translate([0, -30]) { %LidEdgeProfile(); %EdgeProfile(); color("blue") HingeLidProfile(); color("red") HingeBaseProfile(); color("black") translate([0,0,-2]) HingeLeverOuterProfile(); } for (f=[0,1]) { translate([-30, -60 + 30*f]) { translate([0,0,-4]) EdgeProfile(); %translate([0,0,-10]) HingeBaseProfile(); translate([0,-2] * f * hp_k) { translate([0,0,-4]) LidEdgeProfile(); %translate([0,0,-10]) %HingeLidProfile(); } translate(+hppB) rotate([0,0,180*f]) translate(-hppB) { translate([0,0,-2]) color("black") HingeLeverOuterProfile(); translate([0,0,0]) color("red") difference(){ HingeLeverOuterProfile(); HingeLeverInnerProfile(); } translate([0,0,3]) color("yellow") HingeLeverNutProfile(); } } } translate([20,-30]) { %EdgeProfile(); %LidEdgeProfile(); //translate([0,0,1]) CatchCutProfile(); color("blue") CatchCatchProfile(); color("red") difference(){ EdgeProfile(); CatchCutProfile(); } } translate([40,-30]) { difference(){ LidEdgeProfile(); translate(prlp10) PropProfile(10, 1, 0); } translate(prlp10) PropProfile(15, 0); } translate([60,-30]) { PropAggregateProfile(); } } //EdgeProfile(); //KeeperProfile(); //CaseBase(); //%Case(); //Keeper(); //LidEdgeProfile(); //KeeperProfile(); //DemoProfiles(); //PropRecess();