fairphone-case: TestLidTopAperturesPrint: make frameish

[reprap-play.git] / fairphone-case.scad

diff --git a/fairphone-case.scad b/fairphone-case.scad
index beadebd58e78e37a26c0c62a777ef50026007fb7..678ea67cea016a48739b4046521647cdbf232690 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -14,7 +14,18 @@ bumper = [ 0.250, -0.025 ];
 
 enable_support = 1;
 
 
 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_cnr_rad = 6.0;

+phone_rim_depth = 0.80; // includes allowance for a screen protector

 
 button_cutout_depth = 9;
 
 
 button_cutout_depth = 9;
 


@@ -26,9 +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
 
 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
 
 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;
 
 noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
 noisecancelmic_dia = 4.00;
 


@@ -43,10 +58,12 @@ microusb_below = 0.0;
 microusb_width = 16.12 + 1.25;
 
 case_th_bottom = 2.5;
 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;
 
 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;
 case_struts_count = 6;
 case_struts_solid_below = 1.00;
 case_struts_solid_above = 0.75;


@@ -76,14 +93,25 @@ catch_slop = 0.50;
 foldover_gap = 0.50;
 foldover_lever_gap = 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_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_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;
 lever_cover_th = 0.75;
 hingemount_th = 2.5;

+hingemount_wd = 4.8725;

 
 $fa = 5;
 $fs = 0.1;
 
 $fa = 5;
 $fs = 0.1;


@@ -171,7 +199,20 @@ kppa = [ kppb[0], kppf[1] ];
 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
 lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 
 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 ];
 
 lpp12 = [ epp4[0] + lp_r12,    lpp11[1] ];
 lpp13 = [ lpp12[0],            lpp12[1] + lp_r12 ];


@@ -189,9 +230,22 @@ bppO = [ bppN[0], bppP[1] ];
 bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[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
 
 // 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;
 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
 
 
 // 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);
 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;
 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
 
 
 // catch
 


@@ -284,6 +347,26 @@ $prp_r10 = prl_r10;
 
 // ---------- modules ----------
 
 
 // ---------- 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 KeeperProfile(slant=0){
   use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
   polygon([use_e, kppd, kppc, kppb, kppa, kppf]);


@@ -310,7 +393,9 @@ module LidEdgeProfile(){
            lpp12,
            lpp13,
            lpp13 + [10, 0],
            lpp12,
            lpp13,
            lpp13 + [10, 0],

-           lpp10 + [10, 0]
+           lpp15 + [10, 0],
+           lpp15,
+           lpp14,

            ]);
   intersection(){
     circleat(lpp12, r=lp_r12);
            ]);
   intersection(){
     circleat(lpp12, r=lp_r12);


@@ -321,7 +406,10 @@ module LidEdgeProfile(){
 
 module ButtonCoverProfile(){
   intersection(){
 
 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();
     hull(){
       EdgeProfile();
       LidEdgeProfile();


@@ -466,12 +554,13 @@ module CaseAperture(pos, dia, $fn) {
             h = 60);
 }
 
             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;
   // 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;
   eff_y = y_ref_sign > 0 ?         -bumper [1] -y -l/2 :
          y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
          y;


@@ -486,9 +575,9 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 }
 
 module Buttons(){
 }
 
 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();
 }
   Flip_rhs(   ) LidButtonishLeg(14, -1) children();
 //  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 }


@@ -584,19 +673,30 @@ module HingeLeverOuterProfile(){
 }
 
 module HingeLeverInnerProfile(){
 }
 
 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 (x=[-20,20])

-       for (y=[0, c[1] - hppM[1]])
+       for (y=[0, s * 10])

          translate([x,y])
          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)
   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();
 }
     translate(-hinge_origin)
     children();
 }


@@ -781,7 +881,7 @@ module Case(){ ////toplevel
                translate([phone_width/2, -400, kppe[1]])
                mirror([1-abs($rhsflip - keeper_side),0,0])
                cube([400, 800, 50]);
                translate([phone_width/2, -400, kppe[1]])
                mirror([1-abs($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])
              rotate([-90,90,0])
              translate([-400, -400, kppd[1]])
                mirror([0,0,1])


@@ -832,6 +932,12 @@ module Case(){ ////toplevel
   }
 }
 
   }
 }
 

+module LidAdhocMultiprintFrame(phase){
+  if (led_window_style >= 3) {
+    AdhocMultiprintFrame(phase, lpp13[1], -1);
+  }
+}
+

 module Lid(){ ////toplevel
   difference(){
     union(){
 module Lid(){ ////toplevel
   difference(){
     union(){


@@ -872,7 +978,20 @@ module Lid(){ ////toplevel
       hull()
       for (pa = prop_angles)
        PropProfile(pa, 1,1);
       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
 }
 
 module HingeLever(){ ////toplevel


@@ -882,9 +1001,13 @@ module HingeLever(){ ////toplevel
       HingeLeverOuterProfile();
 
     // space for the screws
       HingeLeverOuterProfile();
 
     // space for the screws

-    HingePortion(hex23, hex24)
+    HingePortion(hex26, hex24)

       HingeLeverInnerProfile();
 
       HingeLeverInnerProfile();
 

+    // recesses for the nuts
+    HingePortion(hex23, hex26+1)
+      HingeLeverNutProfile();
+

     // bores for the screws
     HingeScrews();
 
     // bores for the screws
     HingeScrews();
 


@@ -894,8 +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
 module HingeLeverPrint(){ ////toplevel

-  rotate([90,0,0])
+  rotate([-90,0,0])
+    translate([-phone_width/2, phone_height, 0])

     HingeLever();
 }
 
     HingeLever();
 }
 


@@ -1013,6 +1164,8 @@ module TestSelectFrame(){
 
 module TestSelectLidFrame(){
   TestSelectFrame();
 
 module TestSelectLidFrame(){
   TestSelectFrame();

+  translate([led_pos[0], -led_pos[1], -50])
+    cylinder(r= nla_r2+3, h=100);

 }
 
 module TestFrameCase(){ ////toplevel
 }
 
 module TestFrameCase(){ ////toplevel


@@ -1026,6 +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();
 module TestFrameLidPrint(){ ////toplevel
   rotate([0,180,0]) intersection(){
     Lid();


@@ -1097,6 +1280,17 @@ module DemoPropAngles(){ ////toplevel
     DemoPropAngle(prop_angles[i]);
 }
 
     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(); }
 module DemoFrame(){ ////toplevel
   color("red") TestFrameCase();
   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }


@@ -1116,9 +1310,11 @@ module DemoHingedFrame(){ ///toplevel
 }
 
 module DemoHinge(){ ////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
 }
 
 module DemoProfiles(){ ////toplevel


@@ -1152,7 +1348,25 @@ module DemoProfiles(){ ////toplevel
     color("blue") HingeLidProfile();
     color("red")  HingeBaseProfile();
     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
     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]) {
   }
 
   translate([20,-30]) {