chiark / gitweb /
fairphone-case: TestLidTopAperturesPrint: make frameish
[reprap-play.git] / fairphone-case.scad
index 7f4c096..678ea67 100644 (file)
@@ -1,12 +1,31 @@
 // -*- C -*-
 
+include <utils.scad>
+
 phone = [ 75.0, 145.0 ];
 
-bumper = [ 0.250, 0.250 ];
+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;
 
@@ -18,20 +37,33 @@ 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 = [ 13.92, 7.96 ];
-jack_dia = 9.1 + .5; // some jack I had lying around
+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 = 1.75;
+noisecancelmic_dia = 4.00;
+
+//fingerpushhole_dias = [ 15, 18 ];
+fingerpushhole_dias = [];
 
-rearspeaker_pos_bl = [ 14.92, 18.72 ];
+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 = 2.5;
+case_th_lid = 3.0;
 case_th_side = 2;
 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;
@@ -48,21 +80,78 @@ 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;
 
+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;
 
-rearspeaker_gap    = [ 1.0, 1.0 ]; // each side
+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;
+
+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;
 
 // ---------- calculated ----------
 
@@ -71,6 +160,8 @@ 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);
 
@@ -80,6 +171,13 @@ 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
 
@@ -101,11 +199,26 @@ kppa = [ kppb[0], kppf[1] ];
 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 
-lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
+lpp14 = lpp10 + [1,0] * keeper_inner_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 = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
@@ -117,17 +230,141 @@ bppO = [ bppN[0], bppP[1] ];
 bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[1] ];
-
-module rectfromto(a,b) {
-  ab = b - a;
-  translate([min(a[0], b[0]), min(a[1], b[1])])
-    square([abs(ab[0]), abs(ab[1])]);
+bppU = [ bppJ[0], lpp12[1] ];
+bppV = lpp11;
+bppW = lpp10;
+
+// 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);
 }
-module circleat(c,r) { translate(c) circle(r); }
-module linextr(z0,z1) {
-  translate([0,0,z0])
-    linear_extrude(height=z1-z0)
-    children();
+chk(hex20, 6);
+chk(hex21, 10.8725);
+chk(hex22, 10.9975);
+chk(hex23, 13.74);
+chk(hex24, 18.75);
+
+// 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){
@@ -156,7 +393,9 @@ module LidEdgeProfile(){
            lpp12,
            lpp13,
            lpp13 + [10, 0],
-           lpp10 + [10, 0]
+           lpp15 + [10, 0],
+           lpp15,
+           lpp14,
            ]);
   intersection(){
     circleat(lpp12, r=lp_r12);
@@ -167,7 +406,10 @@ module LidEdgeProfile(){
 
 module ButtonCoverProfile(){
   intersection(){
-    polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
+    polygon(concat([ bppM, bppP, bppO, bppJ ],
+                  (enable_support && !$button_suppress_over_keeper
+                   ? [ bppU, bppV, bppW ] : []),
+                  [ bppL, bppK ]));
     hull(){
       EdgeProfile();
       LidEdgeProfile();
@@ -221,7 +463,32 @@ module ButtonPlan(l, deep, cut){
   }
 }
 
-module CaseBase_rhsflip(yn=[0,1]) {
+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])
@@ -230,7 +497,7 @@ module CaseBase_rhsflip(yn=[0,1]) {
   }
 }
 
-module CaseBase_botflip(yn=[0,1]) {
+module Flip_bot(yn=[0,1]) {
   for ($botflip=yn) {
     translate([0, -phone_height/2, 0])
       mirror([0, $botflip, 0])
@@ -241,14 +508,14 @@ module CaseBase_botflip(yn=[0,1]) {
 
 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
   // sides
-  CaseBase_rhsflip(){
+  Flip_rhs(){
     translate([0, -phone_cnr_rad, 0])
       rotate([90,0,0])
       linear_extrude(height = phone_height - phone_cnr_rad*2)
       children(0);
   }
   // corners
-  CaseBase_rhsflip() CaseBase_botflip() {
+  Flip_rhs() Flip_bot() {
     translate([+1,-1] * phone_cnr_rad)
       intersection(){
        rotate_extrude()
@@ -263,7 +530,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
       }
   }
   // top and bottom
-  CaseBase_botflip(){
+  Flip_bot(){
     translate([ phone_width - phone_cnr_rad, 0,0 ])
       rotate([90,0,-90])
       linear_extrude(height = phone_width - phone_cnr_rad*2)
@@ -287,16 +554,17 @@ module CaseAperture(pos, dia, $fn) {
             h = 60);
 }
 
-module SideButton(y, y_ref_sign, l){
+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);
+  //echo(eff_y);
   translate([0, eff_y, 0])
     children();
 }
@@ -307,11 +575,11 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 }
 
 module Buttons(){
-  CaseBase_rhsflip([1]) SideButton(15.580, +1, 8.9) children(); // power
-  CaseBase_rhsflip([1]) SideButton(48.700, -1, 8.920) children(); // camera
-  CaseBase_rhsflip([0]) SideButton(30.800, +1, 21.96) children(); // volume
-  CaseBase_rhsflip(   ) LidButtonishLeg(20, -1) children();
-//  CaseBase_rhsflip([0]) LidButtonishLeg(20, +1, 20) children();
+  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){
@@ -332,13 +600,121 @@ module Struts(x_start, z_min, th){
   }
 }
 
-module RearSpeakerAperture(){
-  CaseBase_rhsflip([1]) CaseBase_botflip([1])
+module OrdinaryRearAperture(rhs,bot, pos){
+  Flip_rhs(rhs) Flip_bot(bot)
     linextr(-20, 20)
     mirror([0,1])
-    translate(rearspeaker_pos_bl + bumper)
+    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(0);
+}
+
+module CatchPortion(width){
+  translate([phone_width/2, 0,0])
+    rotate([90,0,-90])
+    linextr(-width/2, width/2)
+    children(0);
 }
 
 module CaseBase(){
@@ -346,13 +722,109 @@ module CaseBase(){
     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)
-      intersection(){
+      Flip_rhs(1-keeper_side) intersection(){
        rotate([90, 0, 0])
          linear_extrude(height = phone_height + phone_cnr_rad * 2)
          KeeperProfile(1);
@@ -361,14 +833,26 @@ module Case(){ ////toplevel
        translate([0,0, -25])
          linear_extrude(height = 50)
          hull()
-         // CaseBase_rhsflip() // actually, we only care about the LH
-         CaseBase_botflip()
+         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
-    CaseBase_rhsflip(1)
+    Flip_rhs(keeper_side)
       translate([0, -phone_cnr_rad, 0])
       rotate([90, 0, 0])
       linear_extrude(height = phone_height + phone_cnr_rad * 2)
@@ -379,12 +863,7 @@ module Case(){ ////toplevel
       }
 
     // front camera
-    CaseBase_rhsflip([1])
-      mirror([0, 0, 1])
-      linear_extrude(height = 20)
-      mirror([0, 1, 0])
-      translate(bumper)
-      rectfromto(camera_pos_tl, camera_pos_br);
+    RearCameraAperture();
 
     // struts (invisible, because they're buried in the case)
     Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
@@ -392,6 +871,7 @@ module Case(){ ////toplevel
     Buttons(){
       mirror([1,0,0])
        rotate([90,0,90]) {
+         if (!($button_leg_only && enable_support))
          intersection(){
            translate([0,0,-10])
              linear_extrude(height= 20)
@@ -399,20 +879,62 @@ module Case(){ ////toplevel
            if ($button_leg_only)
              rotate([-90,90,0])
                translate([phone_width/2, -400, kppe[1]])
-               mirror([$rhsflip,0,0]) cube([400, 800, 50]);
+               mirror([1-abs($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);
-    CaseBase_rhsflip([1])
-      CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
+    Flip_rhs(1)
+      CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
+
+    OrdinaryRearApertures();
+
+    MicroUSB();
 
-    RearSpeakerAperture();
+    // 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_width + catch_side_gap*2)
+      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);
   }
 }
 
@@ -435,16 +957,116 @@ module Lid(){ ////toplevel
            ButtonCoverProfile();
        }
       }
+
+      // hinge arms
+      HingePortion(hex20, hex21) HingeLidProfile();
+
+      // catch
+      CatchPortion(catch_width)
+       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();
-    translate([-30, -200, -20])
-    cube([30 + 15, 250, 40]);
+    TestSelectLength();
+  }
+}
+
+module TestLengthRight(){ ////toplevel
+  intersection(){
+    Case();
+    Flip_rhs(1)
+      TestSelectLength();
   }
 }
 
@@ -468,23 +1090,27 @@ module TestLidWidthPrint(){ ////toplevel
   }
 }
 
-module TestSelectCamera(){
-  CaseBase_rhsflip(1)
-    translate([0,0,-25])
-    linear_extrude(height = 50)
-    mirror([0, 1, 0])
-    rectfromto([-20, -20],
-              camera_pos_br + bumper + [ 2, 2 ]);
-}
-
-module TestSelectRearSpeaker(){
+module TestSelectRearAperture(){
   minkowski(){
-    RearSpeakerAperture();
+    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();
@@ -536,27 +1162,58 @@ module TestSelectFrame(){
   }
 }
 
+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();
-      TestSelectRearSpeaker();
+      TestSelectOrdinaryRearApertures();
     }
   }
 }
 
-module TestFrameLidPrint(){ ////toplevel
-  rotate([0,0,180]) intersection(){
-    Lid();
+module TestSelectTopApertures(){
+  translate([-100, -35, -100])
+    cube([400, 100, 200]);
+  LidAdhocMultiprintFrame(0);
+  LidAdhocMultiprintFrame(1);
+}
+
+module TestTopApertures(){ ////toplevel
+  intersection(){
+    Case();
     TestSelectFrame();
+    TestSelectTopApertures();
   }
 }
 
-module Keeper(){ ////toplevel
-  CaseBase_rhsflip()
-    OneKeeper();
+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){
@@ -564,6 +1221,102 @@ module ButtonPlanForDemo(z, deep, cut){
     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 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();
@@ -588,6 +1341,54 @@ module DemoProfiles(){ ////toplevel
     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();
@@ -598,3 +1399,4 @@ module DemoProfiles(){ ////toplevel
 //LidEdgeProfile();
 //KeeperProfile();
 //DemoProfiles();
+//PropRecess();