// -*- 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
+// <http://www.gnu.org/licenses/>.
+//
+// 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 <utils.scad>
phone = [ 75.0, 145.0 ];
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;
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;
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;
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_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_real = 1.93;
+hingescrew_nut_thick = 1.93;
hingescrew_head_th = 1.38 + 0.75;
hingescrew_head_dia = 3.92;
-lever_cover_th = 0.75;
-hingemount_th = 2.5;
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;
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 ];
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;
// 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
-hex26 = hex23 + hingescrew_nut_thick_real * 2/3;
-hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_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
-echo(hex20 - 6,
- hex21 - 10.8725,
- hex22 - 10.9975,
- hex23 - 13.74,
- hex24 - 18.75);
-//echo(hingescrew_portion_len);
+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
// ---------- 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]);
lpp12,
lpp13,
lpp13 + [10, 0],
- lpp10 + [10, 0]
+ lpp15 + [10, 0],
+ lpp15,
+ lpp14,
]);
intersection(){
circleat(lpp12, r=lp_r12);
}
}
+module LidEdgeFoldClearanceProfile(){
+ 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 ? [ bppU, bppV, bppW ] : []),
+ (enable_support && !$button_suppress_over_keeper
+ ? [ bppU, bppV, bppW ] : []),
[ bppL, bppK ]));
hull(){
EdgeProfile();
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;
+ $button_suppress_over_keeper= suppress_over_keeper;
eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
y;
}
module Buttons(){
- Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
- Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
- Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
+ Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
+ Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
+ Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
Flip_rhs( ) LidButtonishLeg(14, -1) children();
// Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
}
translate([phone_width/2, -400, kppe[1]])
mirror([1-abs($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])
}
}
+module LidAdhocMultiprintFrame(phase){
+ if (led_window_style >= 3) {
+ AdhocMultiprintFrame(phase, lpp13[1], -1);
+ }
+}
+
+module LidAroundEdges(){
+ AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
+ children();
+}
+
module Lid(){ ////toplevel
+ skew_centre = [0, lpp11[0], lpp11[1]];
difference(){
union(){
- AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
- LidEdgeProfile();
+ intersection(){
+ LidAroundEdges()
+ LidEdgeProfile();
+
+ translate(skew_centre)
+ multmatrix([[ 1, 0, 0, 0 ],
+ [ 0, 1, -2, 0 ],
+ [ 0, 0, 1, 0 ],
+ [ 0, 0, 0, 1 ]])
+ translate(-skew_centre)
+ LidAroundEdges()
+ LidEdgeFoldClearanceProfile();
+ }
// button covers
Buttons(){
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 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])
module TestSelectLidFrame(){
TestSelectFrame();
+ translate([led_pos[0], -led_pos[1], -50])
+ cylinder(r= nla_r2+3, h=100);
}
module TestFrameCase(){ ////toplevel
}
}
+module TestSelectTopApertures(){
+ translate([-100, -35, -100])
+ cube([400, 100, 200]);
+ LidAdhocMultiprintFrame(0);
+ LidAdhocMultiprintFrame(1);
+}
+
module TestTopApertures(){ ////toplevel
intersection(){
Case();
TestSelectFrame();
- translate([-100, -35, -100])
- cube([400, 100, 200]);
+ TestSelectTopApertures();
+ }
+}
+
+module TestLidTopAperturesPrint(){ ////toplevel
+ rotate([0,180,0]) intersection(){
+ Lid();
+ TestSelectLidFrame();
+ TestSelectTopApertures();
+ }
+}
+
+module TestLidWindowTopAperturesPrint(){ ////toplevel
+ rotate([0,180,0]) intersection(){
+ LidWindow();
+ TestSelectTopApertures();
}
}
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(); }
}
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
~ianmdlvl / reprap-play.git / blobdiff