X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=b29207d96b841441403f846dd4b75aba83266e76;hp=f05abd581280566c1079b02947e6320c7c8a8329;hb=c73e8d8c7a09210af369cc6c781e3467724260c0;hpb=e381edc2c421479d7cbfc741521eaa3a459f1554 diff --git a/fairphone-case.scad b/fairphone-case.scad index f05abd5..b29207d 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,25 +1,57 @@ // -*- C -*- -phone_height = 146.5; -phone_width = 76.75; +phone_height = 146.5 - .80; +phone_width = 76.75 - .50; -phone_cnr_rad = 4.0; +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 = [ 7.0, 13.0 ]; // measured from tl corner +camera_pos_br = [ 22.85,37.85]; // tl/br as seen from back -case_th_bottom = 2; -case_th_lid = 2; +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 = 0.75; +case_struts_solid_above = 1.00; +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; $fa = 5; $fs = 0.1; -// calculated +button_l_fudge = 4.5; + +// ---------- calculated ---------- + +// ----- 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; @@ -28,36 +60,132 @@ 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 ]; +lpp12 = [ epp4[0] + lid_lip, lpp11[1] ]; +lpp13 = [ lpp12[0], lpp12[1] + lid_lip ]; + +// 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) { translate(a) square(b - a); } +module rectfromto(a,b) { + ab = b - a; + translate([min(a[0], b[0]), min(a[1], b[1])]) + square([abs(ab[0]), abs(ab[1])]); +} module circleat(c,r) { translate(c) circle(r); } +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=lid_lip); + 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){ + 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]) { + for (rhs=yn) { translate([phone_width/2, 0, 0]) mirror([rhs,0,0]) translate([-phone_width/2, 0, 0]) @@ -74,13 +202,15 @@ module CaseBase_botflip() { } } -module CaseBase(){ +module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ + // sides CaseBase_rhsflip(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) - EdgeProfile(); + children(0); } + // corners CaseBase_rhsflip() CaseBase_botflip() { translate([+1,-1] * phone_cnr_rad) intersection(){ @@ -88,20 +218,187 @@ module CaseBase(){ 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]); } } + // top and bottom CaseBase_botflip(){ 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 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(); +} + +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() + // CaseBase_rhsflip() // actually, we only care about the LH + CaseBase_botflip() + circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2); + } + } + + // slot for keeper + CaseBase_rhsflip(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 + CaseBase_rhsflip([1]) + mirror([0, 0, 1]) + linear_extrude(height = 20) + mirror([0, 1, 0]) + rectfromto(camera_pos_tl, camera_pos_br); + + // struts (invisible, because they're buried in the case) + Struts(epp2i[1] - case_th_bottom, case_th_bottom); + } +} + +module Lid(){ ////toplevel + AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0) + LidEdgeProfile(); +} + +module TestLength(){ ////toplevel + intersection(){ + Case(); + translate([-30, -200, -20]) + cube([30 + 15, 250, 40]); + } +} + +module TestWidth(){ ////toplevel + intersection(){ + Case(); + translate([-30, -(phone_height - 25), -20]) + mirror([0, 1, 0]) + cube([200, 50, 40]); + } +} + +module TestLidWidthPrint(){ ////toplevel + rotate([0,180.0]) + intersection(){ + Lid(); + translate([-30, -(phone_height - 25), -20]) + mirror([0, 1, 0]) + cube([200, 50, 40]); + } +} + +module TestCamera(){ ////toplevel + intersection(){ + Case(); + CaseBase_rhsflip(1) + translate([0,0,-25]) + linear_extrude(height = 50) + mirror([0, 1, 0]) + rectfromto([-20, -20], + camera_pos_br + [ 5, 5 ]); + } +} + +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 Keeper(){ ////toplevel + CaseBase_rhsflip() + 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); + } + } + + translate([-20,0]) { + ButtonPlanForDemo("grey", -1, 0,1); + ButtonPlanForDemo("blue", -2, 1,0); + ButtonPlanForDemo("red", -3, 1,1); } } //EdgeProfile(); -CaseBase(); +//KeeperProfile(); +//CaseBase(); +//%Case(); +//Keeper(); +//LidEdgeProfile(); +//KeeperProfile(); +//DemoProfiles();