chiark / gitweb /
fairphone-case: TestLidTopAperturesPrint: make frameish
[reprap-play.git] / fairphone-case.scad
index 7fe1083..678ea67 100644 (file)
@@ -4,17 +4,9 @@ include <utils.scad>
 
 phone = [ 75.0, 145.0 ];
 
-prop_lid_posns = [ 70 ]; // measured from bottom of phone
+prop_buildout_less = 3;
 
-prop_lengths = [ 80, 50 ];
-
-prop_angle_specs = [
-  // angle    prop length index     prop lid posn index
-  [   15,          1,                    0 ],
-  [   30,          1,                    0 ],
-  [   45,          0,                    0 ],
-  [   60,          0,                    0 ],
-  ];
+prop_angles = [ 15, 30, 45, 60 ];
 
 bumper = [ 0.250, -0.025 ];
 // ^ One side.  Overall size is increased by twice this.
@@ -22,7 +14,18 @@ bumper = [ 0.250, -0.025 ];
 
 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;
 
@@ -34,9 +37,13 @@ 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 = [ 14.38, 7.96 ];
+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;
 
@@ -51,10 +58,12 @@ 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;
@@ -84,14 +93,25 @@ 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_nut_thick = 1.93 + 0.20; // incl. washer
-hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
+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;
@@ -120,16 +140,18 @@ catch_height = 0.35;
 catch_finger_height = 1.5;
 catch_finger_depth = 2.5;
 
-prop_main_width = 3;
+prop_recess_under = 0.50;
+prop_recess_slop = 0.200; // each side
+prop_end_dia = 0.5;
 prop_main_th = 3;
-prop_wing_len = 3;
-prop_nose_slope = 1.5; // bigger means pointier
+prop_taper_len = 6;
+prop_main_width = 4;
 prop_side_gap = 0.75; // each side
-prop_fin_height = 1.5;
-prop_fin_width = 0.75;
-prop_max_angle = 45; // bigger means at worse angle
-prop_recess_under = 0.30;
-prop_backfwd_gap = 1.0; // total
+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 ----------
 
@@ -138,6 +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);
 
@@ -147,10 +171,12 @@ lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
 
 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
 
-prop_nose_len = case_th_lid - prop_recess_under;
-prop_recess_slope = tan(prop_max_angle); // bigger means steeper
-prop_recess_depth = case_th_lid - prop_recess_under;
-prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
+//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
@@ -173,11 +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] ];
@@ -189,9 +230,22 @@ 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;
+
+// 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_dia/2;
+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;
@@ -214,19 +268,28 @@ hppE = [ hppE_x, hppE_y ];
 
 // hinge elevation x coords
 
-hingescrew_portion_len =
-  0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
-
 hex20 = max(epp2o[0],
            phone_cnr_rad,
            kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
-hex21 = hex20 + hingescrew_portion_len;
+hex21 = hex20 + hingemount_wd;
 hex22 = hex21 + hinge_x_gap;
-hex23 = hex22 + hingescrew_portion_len
-  - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
-hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
-//echo(hex20, hex21, hex22, hex23, hex24);
-//echo(hingescrew_portion_len);
+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);
 
 // catch
 
@@ -249,16 +312,61 @@ cppQ = [ cppR[0],
         cppV[1] - (catch_finger_height - cp_rQ) ];
 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
 
-// prop recess
+// 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
 
-prp1 = [0,0]; // by definition
-prp2 = prp1 + [ -prop_recess_slope, -1 ] * prop_recess_depth;
-prp4 = prp1 + [1,0] * prop_recess_width;
-prp3 = [ prp4[0], prp2[1] ];
-prp5 = prp4 + [1,0] * prop_recess_depth;
+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]);
@@ -285,7 +393,9 @@ module LidEdgeProfile(){
            lpp12,
            lpp13,
            lpp13 + [10, 0],
-           lpp10 + [10, 0]
+           lpp15 + [10, 0],
+           lpp15,
+           lpp14,
            ]);
   intersection(){
     circleat(lpp12, r=lp_r12);
@@ -296,7 +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();
@@ -441,12 +554,13 @@ 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;
@@ -461,9 +575,9 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 }
 
 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) children(); // volume
+  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();
 }
@@ -559,19 +673,30 @@ module HingeLeverOuterProfile(){
 }
 
 module HingeLeverInnerProfile(){
-  for (c = [hppT, hppB]) {
-    hull()
+  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, c[1] - hppM[1]])
+       for (y=[0, s * 10])
          translate([x,y])
-           circleat(c, hp_rn);
+           circle(hp_rn);
   }
 }
 
-module Flip_hinge(){
+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([180,0,0])
+    rotate([doflip*180,0,0])
     translate(-hinge_origin)
     children();
 }
@@ -592,55 +717,105 @@ module CatchPortion(width){
     children(0);
 }
 
-module PropRecess(){
-  // origin is nonstandard
-  hwd345 = 0.5*prop_main_width + prop_side_gap;
-  hwd35  = 0.5*prop_fin_width + prop_side_gap;
-  rotate([90,0,90]){
-    linextr(-hwd345, +hwd345)
-      polygon([ prp1,
-               prp2,
-               prp3,
-               prp4,
-               prp4 + [0,10],
-               prp1 + [0,10],
-               ]);
-    linextr(-hwd35, +hwd35)
-      polygon([ prp1,
-               prp3,
-               prp5,
-               prp5 + [0,10],
-               prp1 + [0,10],
-               ]);
-  }
+module CaseBase(){
+  AroundEdges(epp3[1], case_th_bottom, 1)
+    EdgeProfile();
 }
 
-module CasePropRecess(pas) {
-  // destructure entry in prop_angle_specs
-  beta =                 pas[0];
-  b    = prop_lengths  [ pas[1] ];
-  p    = prop_lid_posns[ pas[2]] ;
+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();
+}
 
-  k = hp_k;
-  x = k / (2 * sin(beta/2)) - hppT[0];
-  c = p + x;
+module PropProfile(gamma, cut=0, rot=0){ ////toplevel
+  PropProfileAssignments(gamma){
 
-  // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_non-included_angle_given_(SSA) [25.1.18]
-  // we always want the positive solution because it has a closer to c
-  a = c * cos(beta) + sqrt( b*b - pow(c * sin(beta),2) );
-  q = a - x;
+    //#circleat($prpp3,1);
+    //#circleat($prpp12,1);
 
-  echo(beta, a, b, c);
+    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);
+      }
+    }
+  }
+}
 
-  Flip_bot(1)
-    translate([ phone_width/2, -q, epp2o[1]-case_th_bottom ])
-    rotate([0,180,0])
-    PropRecess();
+module PropAggregateProfile(){
+  for (angle = prop_angles)
+    PropProfile(angle, 0,0);
 }
 
-module CaseBase(){
-  AroundEdges(epp3[1], case_th_bottom, 1)
-    EdgeProfile();
+module Prop(){ ////toplevel
+  hw = prop_main_width/2;
+  linextr(-hw, +hw)
+    PropAggregateProfile();
 }
 
 module Case(){ ////toplevel
@@ -664,6 +839,16 @@ module Case(){ ////toplevel
 
       // 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
@@ -696,7 +881,7 @@ module Case(){ ////toplevel
                translate([phone_width/2, -400, kppe[1]])
                mirror([1-abs($rhsflip - keeper_side),0,0])
                cube([400, 800, 50]);
-           if (enable_support)
+           if (enable_support && !$button_suppress_over_keeper)
              rotate([-90,90,0])
              translate([-400, -400, kppd[1]])
                mirror([0,0,1])
@@ -706,6 +891,7 @@ module Case(){ ////toplevel
            linear_extrude(height= 20)
            ButtonPlan($button_l, 1,1);
         }
+      
     }
 
     // apertures along top edge
@@ -732,9 +918,23 @@ module Case(){ ////toplevel
     CatchPortion(catch_width + catch_side_gap*2)
       CatchCutProfile();
 
-    // prop recesses
-    #for (pas = prop_angle_specs)
-      CasePropRecess(pas);
+    // 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);
   }
 }
 
@@ -770,12 +970,28 @@ module Lid(){ ////toplevel
     // screw holes in the hinge arms
     HingeScrews();
 
-    // prop recesses
-    Flip_bot(1)
-      for (y = prop_lid_posns)
-       translate([ phone_width/2, -y, lpp13[1] ])
-         PropRecess();
-  }
+    // 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
@@ -785,9 +1001,13 @@ module HingeLever(){ ////toplevel
       HingeLeverOuterProfile();
 
     // space for the screws
-    HingePortion(hex23, hex24)
+    HingePortion(hex26, hex24)
       HingeLeverInnerProfile();
 
+    // recesses for the nuts
+    HingePortion(hex23, hex26+1)
+      HingeLeverNutProfile();
+
     // bores for the screws
     HingeScrews();
 
@@ -797,8 +1017,36 @@ module HingeLever(){ ////toplevel
   }
 }
 
+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])
+  rotate([-90,0,0])
+    translate([-phone_width/2, phone_height, 0])
     HingeLever();
 }
 
@@ -903,19 +1151,6 @@ module LidPrint(){ ////toplevel
     Lid();
 }
 
-module TestSelectPropRecesses(posns){
-  linextr(-100,100){
-    translate([phone_width/2, -phone_height]){
-      square([ 3, 500 ], center=true);
-      for (y=posns)
-       hull()
-         for (dy=[ -prp5[0], -prp2[0] ])
-           translate([0,y+dy])
-             square([prop_main_width+5, 5], center=true);
-    }
-  }
-}
-
 module TestSelectFrame(){
   include = [1,-1] * (epp2i[0] + 4);
 
@@ -929,7 +1164,8 @@ module TestSelectFrame(){
 
 module TestSelectLidFrame(){
   TestSelectFrame();
-  TestSelectPropRecesses(prop_lid_posns);
+  translate([led_pos[0], -led_pos[1], -50])
+    cylinder(r= nla_r2+3, h=100);
 }
 
 module TestFrameCase(){ ////toplevel
@@ -943,6 +1179,36 @@ module TestFrameCase(){ ////toplevel
   }
 }
 
+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();
@@ -972,6 +1238,59 @@ module HingeScrews(){
   }
 }
 
+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(); }
@@ -991,9 +1310,11 @@ module DemoHingedFrame(){ ///toplevel
 }
 
 module DemoHinge(){ ////toplevel
-  DemoFrame();
-  translate([0,0, -hp_k*3])
-    DemoHingedFrame();
+  translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
+    DemoFrame();
+    translate([0,0, -hp_k*3])
+      DemoHingedFrame();
+  }
 }
 
 module DemoProfiles(){ ////toplevel
@@ -1027,7 +1348,25 @@ module DemoProfiles(){ ////toplevel
     color("blue") HingeLidProfile();
     color("red")  HingeBaseProfile();
     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
-    color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
+  }
+
+  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]) {
@@ -1037,6 +1376,19 @@ module DemoProfiles(){ ////toplevel
     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();