fairphone-case: break out Struts (nfc)

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

diff --git a/fairphone-case.scad b/fairphone-case.scad
index 6b76344472d4eddd024b0d5ab4ce01440e9a09ef..b29207d96b841441403f846dd4b75aba83266e76 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -1,7 +1,7 @@
 // -*- C -*-
 
 phone_height = 146.5 - .80;
-phone_width = 76.75;
+phone_width = 76.75 - .50;
 
 phone_cnr_rad = 6.0;
 
@@ -13,7 +13,7 @@ phone_backside_slope_inner = 1.5; // larger means shallower
 phone_backside_slope_outer = 1.0; // larger means shallower
 
 camera_pos_tl = [  7.0, 13.0 ]; // measured from tl corner
-camera_pos_br = [ 24.0, 39.5 ]; // tl/br as seen from back
+camera_pos_br = [ 22.85,37.85]; // tl/br as seen from back
 
 case_th_bottom = 2.5;
 case_th_lid = 2.5;
@@ -27,8 +27,9 @@ case_struts_width = 0.10;
 
 keeper_th_z = 0.75;
 keeper_th_x = 0.75;
-keeper_inner_width = 1.75;
-keeper_inner_height = 1.75;
+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;
@@ -44,9 +45,11 @@ lid_lip = 1.75;
 $fa = 5;
 $fs = 0.1;
 
-// calculated
+button_l_fudge = 4.5;
 
-// could be changed
+// ---------- calculated ----------
+
+// ----- could be changed -----
 lid_buttoncover_gap = lid_gap_x;
 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
 
@@ -75,13 +78,17 @@ lpp11 = [ lpp10[0],            epp5[1] + lid_gap_z ];
 lpp12 = [ epp4[0] + lid_lip,   lpp11[1] ];
 lpp13 = [ lpp12[0],            lpp12[1] + lid_lip ];
 
-bppM = epp4 + [0,1] * lid_gap_z;
+// button profile
+bppM = epp4 + [0,5];
 bppN = [ 0.5 * (epp0[0] + epp4[0]), 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] ];
 
 module rectfromto(a,b) {
   ab = b - a;
@@ -90,8 +97,9 @@ module rectfromto(a,b) {
 }
 module circleat(c,r) { translate(c) circle(r); }
 
-module KeeperProfile(){
-  polygon([kppe, 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]);
 }
 
 module EdgeProfile(){
@@ -124,7 +132,56 @@ module LidEdgeProfile(){
   }
 }
 
-module ButtonPlan(){
+module ButtonCoverProfile(){
+  intersection(){
+    polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
+    hull(){
+      EdgeProfile();
+      LidEdgeProfile();
+    }
+  }
+}
+
+module ButtonPlan(l, deep, cut){
+  bigger =
+    (deep ? lid_buttoncover_overlap : 0) +
+    (cut  ? 0 : -lid_buttoncover_gap);
+
+  d_D1_y =
+    (cut  ? 0 : lid_buttoncover_gap);
+
+  C = [0,0]; // by definition
+  T = [ 0, epp4[1] ];
+  G = T + [0,10];
+  B0 = C + [0,-1] * button_cutout_depth;
+  r0 = 0.5 * (T[1] - B0[1]);
+  A = [  -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
+  r1 = r0 + bigger;
+  // | D1 - A | = r1 * 2
+  // D1_y = T_y - r1 + d_D1_y
+  // =>    4 * r1^2   =  (r1-r0 + d_D1_y)^2 + (D1_x - A_x)^2
+  // =>    D1_x =  A_x + v/~ [  4 * r1^2   -   (r1-r0 + d_D1_y)^2 ]
+  D1  = [ A[0] - sqrt( 4*r1*r1 - pow(bigger + d_D1_y, 2) ),
+         T[1] - r1 + d_D1_y ];
+  E1  = 0.5 * (D1 + A);
+  F1  = D1 + [0,10];
+
+  hull(){
+    for (m=[0,1]) mirror([m,0])
+      circleat(A, r1);
+  }
+  for (m=[0,1]) mirror([m,0]) {
+    difference(){
+      polygon([ E1,
+               A,
+               B0,
+               G,
+               F1,
+               D1
+               ]);
+      circleat(D1, r1);
+    }
+  }
 }
 
 module CaseBase_rhsflip(yn=[0,1]) {
@@ -183,6 +240,18 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
               [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 }
 
+module Struts(z_min, th){
+  for (i= [1 : 1 : case_struts_count]) {
+    translate([0,
+              -phone_height * i / (case_struts_count+1),
+              z_min + case_struts_solid_below])
+      linear_extrude(height= th
+                    -(case_struts_solid_below+case_struts_solid_above))
+      rectfromto([               epp2i[0], -0.5 * case_struts_width ],
+                [ phone_width - epp2i[0], +0.5 * case_struts_width ]);
+  }
+}
+
 module CaseBase(){
   AroundEdges(epp3[1], case_th_bottom, 1)
     EdgeProfile();
@@ -197,7 +266,7 @@ module Case(){ ////toplevel
       intersection(){
        rotate([90, 0, 0])
          linear_extrude(height = phone_height + phone_cnr_rad * 2)
-         KeeperProfile();
+         KeeperProfile(1);
 
        // outline of the whole case, to stop it protruding
        translate([0,0, -25])
@@ -228,15 +297,7 @@ module Case(){ ////toplevel
       rectfromto(camera_pos_tl, camera_pos_br);
 
     // struts (invisible, because they're buried in the case)
-    for (i= [1 : 1 : case_struts_count]) {
-      translate([0,
-                -phone_height * i / (case_struts_count+1),
-                epp2i[1] - case_th_bottom + case_struts_solid_below])
-       linear_extrude(height= case_th_bottom
-                      -(case_struts_solid_below+case_struts_solid_above))
-       rectfromto([               epp2i[0], -0.5 * case_struts_width ],
-                  [ phone_width - epp2i[0], +0.5 * case_struts_width ]);
-    }
+    Struts(epp2i[1] - case_th_bottom, case_th_bottom);
   }
 }
 
@@ -301,15 +362,35 @@ module Keeper(){ ////toplevel
     OneKeeper();
 }
 
+module ButtonPlanForDemo(colour, z, deep, cut){
+  color(colour)
+    translate([0,0,z])
+    ButtonPlan(8, deep, cut);
+}
+
 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);
+    }
+  }
 
-  color("blue") rectfromto(bppM, bppO);
-  color("red") {
-    rectfromto(bppQ, [ bppS[0], bppQ[1] - 0.1]);
-    rectfromto(bppR, [ bppS[0], bppQ[1] - 0.1]);
+  translate([-20,0]) {
+    ButtonPlanForDemo("grey", -1, 0,1);
+    ButtonPlanForDemo("blue", -2, 1,0);
+    ButtonPlanForDemo("red",  -3, 1,1);
   }
 }