X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=2b77f9b284ad4bba2140d6087e406a010b4c85c7;hp=577f76b52ba71e4564d0a47cfefac7e580a0e1b4;hb=fcf81b2e44a44a2d818c4782ddee1ce10d2c0c2f;hpb=dbd8c08c28a54854238c4ed1aad4f1c572999ebe diff --git a/fairphone-case.scad b/fairphone-case.scad index 577f76b..ea8207e 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,25 +1,102 @@ // -*- C -*- -phone_height = 146.5; -phone_width = 76.75; +include -phone_cnr_rad = 4.0; +phone = [ 75.0, 145.0 ]; + +bumper = [ 0.250, -0.025 ]; +// ^ One side. Overall size is increased by twice this. +// If no bumpers, is the gap around the phone. + +phone_cnr_rad = 6.0; + +button_cutout_depth = 9; phone_edge_thick = 9.0; phone_total_thick = 12.0; -phone_backside_slope = 1.0; // larger means shallower +phone_backside_slope_inner = 1.5; // larger means shallower +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 + +noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs +noisecancelmic_dia = 1.75; + +fingerpushhole_dias = [ 14, 17 ]; -case_th_bottom = 2; -case_th_lid = 2; +rearspeaker_pos_bl = [ 14.92, 18.72 ]; +rearspeaker_size = [ 3.76, 7.36 ]; + +case_th_bottom = 2.5; +case_th_lid = 2.5; case_th_side = 2; case_th_lip = 1.2; -case_lip = 2; +case_struts_count = 6; +case_struts_solid_below = 1.00; +case_struts_solid_above = 0.75; +case_struts_width = 0.10; + +keeper_th_z = 0.75; +keeper_th_x = 0.75; +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; +keeper_gap_x = 0.25; +keeper_gap_x_holes = 0.75; + +case_lip = 1.25; + +lid_gap_x = 0.25; +lid_gap_z = 0.25; +lid_lip = 1.75; + +foldover_gap = 0.50; +foldover_lever_gap = 0.50; + +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_head_th = 1.38 + 0.75; +lever_cover_th = 0.75; +hingemount_th = 2.5; $fa = 5; $fs = 0.1; -// calculated +button_l_fudge = 4.4; +buttonishleg_default_l_is_fudge = 10; + +strut_min_at_end = 1.5; + +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 = [ 1.0, 1.0 ]; // each side + +// ---------- calculated ---------- + +phone_width = (phone + bumper*2)[0]; +phone_height = (phone + bumper*2)[1]; + +inside_br = [phone_width, -phone_height]; + +//echo(camera_pos_tl + bumper, +// camera_pos_br + bumper); + +// ----- could be changed ----- +lid_buttoncover_gap = lid_gap_x; +lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top; phone_backside_slope_thick = phone_total_thick - phone_edge_thick; @@ -28,80 +105,642 @@ phone_backside_slope_thick = phone_total_thick - phone_edge_thick; epp0 = [0,0]; epp1 = [0, -phone_edge_thick]; -epp2 = epp1 + phone_backside_slope_thick * [ phone_backside_slope, -1 ]; -epp3 = epp2 + [10, 0]; -epp4 = epp0 - [1,0] * (case_th_side - case_th_lip); -epp5 = epp0 + [1,0] * case_lip; -epp6 = epp5 + [0,1] * case_th_lip; +epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ]; +epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ]; +epp3 = epp2i + [10, 0]; +epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip); +epp4 = epp5 + [-1,0] * case_th_side; + +kppe = [0,0]; +kppd = kppe + [1,0] * keeper_inner_width; +kppc = kppd + [0,1] * keeper_th_z; +kppb = [ kppe[0] - keeper_th_x, kppc[1] ]; +kppf = kppe - [0,1] * keeper_inner_height; +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]); -module rectfromto(a,b) { translate(a) square(b - a); } -module circleat(c,r) { translate(c) circle(r); } +lpp12 = [ epp4[0] + lp_r12, lpp11[1] ]; +lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ]; + +// 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] ]; + +// hinge plan +hp_rn = hingescrew_nut_dia/2; +hp_r2 = hp_rn + lever_cover_th; +hp_rs = hingescrew_shaft_dia/2; +hp_r1 = hp_rs + hingemount_th; + +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 + 0.5 * [0,+1] * hp_k; +hppB = hppM + 0.5 * [0,-1] * hp_k; + +// 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; +hex22 = hex21 - hinge_x_gap; +hex23 = hex22 + hingescrew_portion_len; +hex24 = hex23 + hinge_x_postscrew_gap; + +// ---------- modules ---------- + +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(){ difference(){ hull(){ - circleat(epp3, r=case_th_bottom); - circleat(epp2, r=case_th_bottom); + translate(epp3) square(case_th_bottom*2, center=true); + circleat(epp2o, r=case_th_bottom); circleat(epp1, r=case_th_side); - circleat(epp4, r=case_th_lip); - rectfromto(epp0, epp6); + rectfromto(epp0, epp4); } - polygon([ epp6 + [10,10], - epp6 + [0,10], - epp5, - epp0, + polygon([ epp5 + [0,10], epp1, - epp2, + epp2i, epp3 + [10,0] ]); } } -module CaseBase_rhsflip() { - for (rhs=[0,1]) { +module LidEdgeProfile(){ + polygon([ lpp10, + lpp11, + lpp12, + lpp13, + lpp13 + [10, 0], + lpp10 + [10, 0] + ]); + intersection(){ + circleat(lpp12, r=lp_r12); + rectfromto( lpp12 + [-10, 0], + lpp12 + [+10, +10] ); + } +} + +module ButtonCoverProfile(){ + intersection(){ + polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]); + hull(){ + EdgeProfile(); + LidEdgeProfile(); + } + } +} + +module ButtonPlan(l, deep, cut){ + epsilon = + (cut ? 0 : lid_buttoncover_gap); + + delta = + (deep ? lid_buttoncover_overlap : 0); + + C = [0,0]; // by definition + T = [ 0, epp4[1] ]; + G = T + [0,10]; + + B0 = C + [0,-1] * button_cutout_depth; + B1 = B0 + [0,1] * epsilon; + + r0 = 0.5 * (T[1] - B0[1]); + A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ]; + H = A + [0,-1] * delta; + + D = A + [-2,0] * r0; + F = D + [0,10]; + + E0 = 0.5 * (D + A); + E1 = E0 + [1,0] * epsilon; + + I0 = [ E0[0], H[1] ]; + I1 = [ E1[0], H[1] ]; + + hull(){ + for (m=[0,1]) mirror([m,0]) + circleat(H, r0 - epsilon); + } + for (m=[0,1]) mirror([m,0]) { + difference(){ + polygon([ E1, + I1, + H, + B1, + G, + F, + D + ]); + circleat(D, r0 + epsilon); + } + } +} + +module Flip_rhs(yn=[0,1]) { + for ($rhsflip=yn) { translate([phone_width/2, 0, 0]) - mirror([rhs,0,0]) + mirror([$rhsflip,0,0]) translate([-phone_width/2, 0, 0]) children(); } } -module CaseBase_botflip() { - for (bot=[0,1]) { +module Flip_bot(yn=[0,1]) { + for ($botflip=yn) { translate([0, -phone_height/2, 0]) - mirror([0, bot, 0]) + mirror([0, $botflip, 0]) translate([0, phone_height/2, 0]) children(); } } -module CaseBase(){ - CaseBase_rhsflip(){ +module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ + // sides + Flip_rhs(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) - EdgeProfile(); + children(0); } - CaseBase_rhsflip(){ + // corners + Flip_rhs() Flip_bot() { translate([+1,-1] * phone_cnr_rad) intersection(){ rotate_extrude() intersection(){ mirror([1,0,0]) translate([-1,0] * phone_cnr_rad) - EdgeProfile(); + children(0); rectfromto([0,-20],[10,20]); } translate([-10, 0, -20] + 0.01 * [+1,-1, 0] ) cube([10,10,40]); } } - CaseBase_botflip(){ + // top and bottom + Flip_bot(){ translate([ phone_width - phone_cnr_rad, 0,0 ]) rotate([90,0,-90]) linear_extrude(height = phone_width - phone_cnr_rad*2) - EdgeProfile(); + children(0); + } + // fill + translate([0,0, fill_zstart]) + mirror([0,0, fill_downwards]) + linear_extrude(height = fill_th) + rectfromto([+1,-1] * phone_cnr_rad, + [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad); +} + +module CaseAperture(pos, dia, $fn) { + theta = 180/$fn; + translate([ pos[0] + bumper[0], + -epp2i[0], + -pos[1] ]) + rotate([-90, theta, 0]) + cylinder(r = dia/2 / cos(theta), + h = 60); +} + +module SideButton(y, y_ref_sign, 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; + 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); + translate([0, eff_y, 0]) + children(); +} + +module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { + $button_leg_only = true; + SideButton(y, y_ref_sign, l) children(); +} + +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( ) LidButtonishLeg(20, -1) children(); +// Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); +} + +module Struts(x_start, z_min, th){ + // if th is negative, starts at z_min and works towards -ve z + // and object should then be printed other way up + for (i= [1 : 1 : case_struts_count]) { + translate([0, + 0, + z_min]) + mirror([0,0, th<0 ? 1 : 0]) + translate([0, + -phone_height * i / (case_struts_count+1), + case_struts_solid_below]) + linear_extrude(height= abs(th) + -(case_struts_solid_below+case_struts_solid_above)) + rectfromto([ x_start, -0.5 * case_struts_width ], + [ phone_width - x_start, +0.5 * case_struts_width ]); + } +} + +module OrdinaryRearAperture(rhs,bot, pos){ + Flip_rhs(rhs) Flip_bot(bot) + linextr(-20, 20) + mirror([0,1]) + translate(pos + bumper) + children(); +} + +module OrdinaryRearApertures(){ + // rear speaker + OrdinaryRearAperture(1,1, rearspeaker_pos_bl) + rectfromto(-rearspeaker_gap, + rearspeaker_size + rearspeaker_gap); + + // finger hole to remove phone + 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(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 (c = [hppT, hppB]) { + hull() + for (x=[0,20]) + translate([x,0]) + circleat(c, hp_rn); + circleat(hppB, hp_rn); + } +} + +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 CaseBase(){ + AroundEdges(epp3[1], case_th_bottom, 1) + EdgeProfile(); +} + +module Case(){ ////toplevel + difference(){ + union(){ + CaseBase(); + + // ledge (fixed keeper) + intersection(){ + rotate([90, 0, 0]) + linear_extrude(height = phone_height + phone_cnr_rad * 2) + KeeperProfile(1); + + // outline of the whole case, to stop it protruding + translate([0,0, -25]) + linear_extrude(height = 50) + hull() + // Flip_rhs() // actually, we only care about the LH + Flip_bot() + circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); + } + + // hinge + HingePortion(hex20, hex21) HingeBaseProfile(); + } + + // slot for keeper + Flip_rhs(1) + translate([0, -phone_cnr_rad, 0]) + rotate([90, 0, 0]) + linear_extrude(height = phone_height + phone_cnr_rad * 2) + minkowski(){ + KeeperProfile(); + rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ], + [ keeper_gap_x_holes, +keeper_gap_z_top ]); + } + + // front camera + RearCameraAperture(); + + // struts (invisible, because they're buried in the case) + Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom); + + Buttons(){ + mirror([1,0,0]) + rotate([90,0,90]) { + intersection(){ + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($button_l, 0,1); + if ($button_leg_only) + rotate([-90,90,0]) + translate([phone_width/2, -400, kppe[1]]) + mirror([$rhsflip,0,0]) cube([400, 800, 50]); + } + translate([0,0, -bppR[0]]) + linear_extrude(height= 20) + ButtonPlan($button_l, 1,1); + } + } + + // apertures along top edge + CaseAperture(jack_pos, jack_dia, 8); + Flip_rhs(1) + CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20); + + OrdinaryRearApertures(); + + // 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, $fn= 8); + } + } +} + +module Lid(){ ////toplevel + difference(){ + union(){ + AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0) + LidEdgeProfile(); + + // button covers + Buttons(){ + intersection(){ + rotate([90,0,90]) + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($button_l, 1,0); + rotate([90,0,0]) + translate([0,0,-100]) + linear_extrude(height= 200) + ButtonCoverProfile(); + } + } + + // hinge arms + HingePortion(hex20, hex21) HingeLidProfile(); + } + Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid); + } +} + +module TestSelectLength(){ + translate([-30, -200, -20]) + cube([30 + 15, 250, 40]); +} + +module TestLength(){ ////toplevel + intersection(){ + Case(); + TestSelectLength(); + } +} + +module TestLengthRight(){ ////toplevel + intersection(){ + Case(); + Flip_rhs(1) + TestSelectLength(); + } +} + +module TestSelectWidth(){ + translate([-30, -(phone_height - 25), -20]) + mirror([0, 1, 0]) + cube([200, 50, 40]); +} + +module TestWidth(){ ////toplevel + intersection(){ + Case(); + TestSelectWidth(); + } +} + +module TestLidWidthPrint(){ ////toplevel + rotate([0,180.0]) intersection(){ + Lid(); + TestSelectWidth(); + } +} + +module TestSelectRearAperture(){ + minkowski(){ + 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(); + TestSelectCamera(); + } +} + +module TestLidByCamera(){ ////toplevel + intersection(){ + Lid(); + TestSelectCamera(); + } +} + +module TestLidByCameraPrint(){ ////toplevel + rotate([180,0,0]) TestLidByCamera(); +} + +module DemoByCamera(){ ////toplevel + color("blue") TestLidByCamera(); + color("red") TestCamera(); +} + +module OneKeeper(){ ////toplevel + translate([0, -phone_cnr_rad, 0]) + rotate([90, 0, 0]) + linear_extrude(height = phone_height - phone_cnr_rad * 2) + KeeperProfile(); +} + +module OneKeeperPrint(){ ////toplevel + rotate([0,180,0]) + OneKeeper(); +} + +module LidPrint(){ ////toplevel + rotate([0,180,0]) + Lid(); +} + +module TestSelectFrame(){ + include = [1,-1] * (epp2i[0] + 4); + + difference(){ + cube(1000, center=true); + translate([0,0, -100]) + linear_extrude(height=200) + rectfromto(include, inside_br - include); + } +} + +module TestFrameCase(){ ////toplevel + intersection(){ + Case(); + union(){ + TestSelectFrame(); + TestSelectCamera(); + TestSelectOrdinaryRearApertures(); + } + } +} + +module TestFrameLidPrint(){ ////toplevel + rotate([0,0,180]) intersection(){ + Lid(); + TestSelectFrame(); + } +} + +module Keeper(){ ////toplevel + Flip_rhs() + OneKeeper(); +} + +module ButtonPlanForDemo(z, deep, cut){ + translate([0,0,z]) + ButtonPlan(8, deep, cut); +} + +module DemoFrame(){ ////toplevel + color("red") TestFrameCase(); + color("blue") intersection(){ Lid(); TestSelectFrame(); } +} + +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); + } + } + + translate([-20,0]) { + color("black") ButtonPlanForDemo(-2, 0,1); + 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(); + color("orange") translate([0,0,-1]) HingeLeverInnerProfile(); } } //EdgeProfile(); -CaseBase(); +//KeeperProfile(); +//CaseBase(); +//%Case(); +//Keeper(); +//LidEdgeProfile(); +//KeeperProfile(); +//DemoProfiles();