X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=d83c53474f4b548972d672539cecb5210bf28c8b;hp=097117757ccdee824a8de9147ec5459a196f5285;hb=1e5609f5812a3103813be78c322b383c8a13d35b;hpb=dd964deea2e03e3c1b57d772e07374046c25e23d diff --git a/fairphone-case.scad b/fairphone-case.scad index 0971177..d83c534 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,6 +1,124 @@ // -*- 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 +// . +// +// 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 +include phone = [ 75.0, 145.0 ]; @@ -21,7 +139,7 @@ led_window_style = 3; // 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 = 0.125; // ^ 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; @@ -40,8 +158,8 @@ camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back jack_pos = [ 13.83, 8.485 ]; jack_dia = 10.64 + .5; // some jack I had lying around -led_pos = [ 12.50, 8.00 ]; -led_aperture = 5; +led_pos = [ 13.98, 10.00 ]; +led_aperture = 9; led_window_ledge = 0.75; // each side noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs @@ -50,6 +168,9 @@ noisecancelmic_dia = 4.00; //fingerpushhole_dias = [ 15, 18 ]; fingerpushhole_dias = []; +lanyard_half_dia = 1.15; +lanyard_entry_rel_breadth = 2; +lanyard_channel_len = 15; rearspeaker_pos_bl = [ 12.64, 18.72 ]; rearspeaker_size = [ 3.76, 7.36 ]; @@ -59,9 +180,11 @@ microusb_width = 16.12 + 1.25; case_th_bottom = 2.5; case_th_lid = 3.0; -case_th_side = 2; +case_th_side = 2.3; 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; @@ -85,6 +208,8 @@ case_lip = 1.25; lid_gap_x = 0.25; lid_gap_z = 0.25; lid_lip = 1.75; +lid_edgepart_width = 5.0; +lid_buttoncover_thick = 1.3; catch_slop = 0.50; @@ -130,13 +255,16 @@ rearspeaker_gap = [ 2.0, 2.0 ]; // each side catch_len = 7.5; catch_width = 15; -catch_thickness = 1.0; +catch_thickness = 1.3; catch_side_gap = 0.75; // each side -catch_depth = 0.75; +catch_depth = 1.25; catch_height = 0.35; catch_finger_height = 1.5; catch_finger_depth = 2.5; +catch_catch_slope = 0.25; + +catch_topcurve_r = 5.0; prop_recess_under = 0.50; prop_recess_slop = 0.200; // each side @@ -151,6 +279,8 @@ prop_caserecess_taper = 0.45; // one side only prop_prop_gap = 0.5; prop_prong_heel_slope = 0.5; +lid_fold_clearance_antislop = 0.5; + // ---------- calculated ---------- phone_width = (phone + bumper*2)[0]; @@ -197,11 +327,12 @@ kppa = [ kppb[0], kppf[1] ]; lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ]; lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ]; -lpp14 = lpp10 + [1,0] * keeper_inner_width; +lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_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 ]; + 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 @@ -218,7 +349,7 @@ case_bottom_z = epp2o[1] - case_th_bottom; // button profile bppM = epp4 + [0,5]; -bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ]; +bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ]; bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ]; bppS = [ epp1[0], bppR[1] ]; bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ]; @@ -231,6 +362,8 @@ bppU = [ bppJ[0], lpp12[1] ]; bppV = lpp11; bppW = lpp10; +echo("BUTTON COVER TH", bppO[0] - bppP[0]); + // notification led aperture nla_r0 = led_aperture/2; @@ -288,6 +421,12 @@ chk(hex22, 10.9975); chk(hex23, 13.74); chk(hex24, 18.75); +lid_fold_clearance_skew = + (lpp10[1] - hppB[1]) / + (lpp10[0] - hppB[0]); + +echo("SK",lid_fold_clearance_skew); + // catch cppJ = [ epp4[0] + catch_thickness, lpp10[1] ]; @@ -298,7 +437,7 @@ cppP = [ epp4[0], cppJ[1] ]; cppS = cppJ + [0,-1] * catch_len; cppD = [ cppA[0], cppS[1] + catch_slop ]; cppC = [ cppB[0], cppD[1] ]; -cppT = cppS + [1,0] * catch_depth; +cppT = cppS + [1, -catch_catch_slope] * catch_depth; cppU = cppT + [0,-1] * catch_height; cppV = [ cppS[0], cppU[1] - catch_depth ]; @@ -309,6 +448,23 @@ cppQ = [ cppR[0], cppV[1] - (catch_finger_height - cp_rQ) ]; cppF = [ cppV[0] + catch_finger_depth, cppC[1] ]; +// lanyard + +ly_r = lanyard_half_dia / 2; +ly_rc = ly_r * 2; + +ly_theta = -atan2vector(epp2i - epp1); +ly_o = epp2i + 3 * ly_r * unitvector2d(epp1 - epp2i); + +max_case_bottom_edge_thickness = + case_th_bottom + + sin(ly_theta) * (epp2i-epp2o)[0]; + +ly_q_z = -(ly_rc + ly_r); +ly_re = max_case_bottom_edge_thickness - (-ly_q_z); + +ly_oec_y = lanyard_entry_rel_breadth * ly_r; + // prop recess in case prop_x_pos = phone_width/2; @@ -346,11 +502,11 @@ $prp_r10 = prl_r10; module AdhocMultiprintFrame(phase, z0, zs) { // from z0 to z0 + zs*layer - extra = phase * 0.65 + 5; + 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; + yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra; p0 = [ xrange[0], yrange[0] ]; p1 = [ xrange[1], yrange[1] ]; echo(p0, p1); @@ -384,6 +540,108 @@ module EdgeProfile(){ } } +module LanyardLanyardProfile(entry=false){ + hull(){ + for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1)) + translate(xs * 0.5 * lanyard_half_dia * [1,0]) + circle(r= lanyard_half_dia/2); + } +} + +module LanyardCurveChannelProfile(){ + translate([0, -ly_r]) + LanyardLanyardProfile(); +} + +module LanyardEntryChannelProfile(){ + LanyardLanyardProfile(true); +} + +module LanyardMainChannelProfile(){ + LanyardCurveChannelProfile(); + difference(){ + square(center=true, ly_r * [6, 2]); + for (xs=[-1,+1]) + translate(ly_r * [3 * xs, -1]) + circle(r = ly_r); + } +} + +module LanyardEntryOuterProfile(){ + circleat([ly_re + ly_r, 0], ly_re); +} + +module LanyardEntry(){ + q_z = ly_q_z; + oec_y = ly_oec_y; + + d_x = -ly_rc; + + translate([d_x, 0, q_z]) { + intersection(){ + rotate([90,0,0]) + rotate_extrude(convexity=10) + rotate(90) + translate([0, -q_z]) + LanyardCurveChannelProfile(); + translate([0,-10,0]) + cube([20,20,20]); + } + } + + mirror([0,0,1]) + translate([0,0,-1]) + linear_extrude(height=20) + rotate(-90) + LanyardEntryChannelProfile(); + + translate([0, ly_r*2, 0]) + rotate([90,0,0]) + linear_extrude(height = ly_r*4){ + difference(){ + rectfromto([d_x, q_z], [ly_r, 0]); + circleat([d_x, q_z], ly_rc); + } + } + + translate([0,0,q_z]){ + for (my=[0,1]) + mirror([0,my,0]){ + translate([0, oec_y, 0]){ + difference(){ + translate(ly_re * [-1,0,-2]) + cube(ly_re * [2,1,2]); + rotate_extrude(convexity=10) + LanyardEntryOuterProfile(); + } + } + } + difference(){ + translate([-ly_re, -(oec_y + 0.01), -2*ly_re]) + cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]); + for (mx=[0,1]) + mirror([mx,0,0]) + rotate([90,0,0]) + translate([0,0,-10]) + linear_extrude(height=20) + LanyardEntryOuterProfile(); + } + } +} + +module LanyardCutout(l){ + rotate([0,-90,0]) + linear_extrude(height=l) + rotate(-90) + LanyardMainChannelProfile(); + + for (ee=[0,1]){ + translate(ee * l * [-1,0]) + mirror([ee,0,0]) + LanyardEntry(); + } +} + module LidEdgeProfile(){ polygon([ lpp10, lpp11, @@ -401,10 +659,21 @@ module LidEdgeProfile(){ } } +module LidEdgeFoldClearanceProfile(){ + translate([-lid_fold_clearance_antislop, 0]) + 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(); @@ -550,12 +819,13 @@ module CaseAperture(pos, dia, $fn) { 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; + $button_suppress_over_keeper= suppress_over_keeper; eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 : y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 : y; @@ -570,9 +840,9 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { } module Buttons(){ - Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power - Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera - Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume + Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power + Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera + Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume Flip_rhs( ) LidButtonishLeg(14, -1) children(); // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); } @@ -702,14 +972,31 @@ module HingePortion(x0,x1){ mirror([1,0,0]) rotate([90,0,-90]) linear_extrude(height=x1-x0) - children(0); + children(); } -module CatchPortion(width){ - translate([phone_width/2, 0,0]) - rotate([90,0,-90]) - linextr(-width/2, width/2) - children(0); +module CatchPortion(xwidth, ztop){ + width = catch_width + xwidth; + w = width + catch_topcurve_r*2 + 1; + translate([phone_width/2, 0,0]){ + difference(){ + rotate([90,0,-90]) + linextr(-w/2, w/2) + children(0); + translate([0, 50, 0]) + rotate([90,0,0]) + linear_extrude(height=100){ + for (m=[0,1]) mirror([m,0,0]) { + hull(){ + translate([w/2, ztop - catch_topcurve_r]) + circle(catch_topcurve_r); + translate([w/2, -50]) + square(catch_topcurve_r*2, center=true); + } + } + } + } + } } module CaseBase(){ @@ -765,7 +1052,7 @@ module PropProfileAssignments(gamma){ children(); } -module PropProfile(gamma, cut=0, rot=0){ ////toplevel +module PropProfile(gamma, cut=0, rot=0){ PropProfileAssignments(gamma){ //#circleat($prpp3,1); @@ -876,7 +1163,7 @@ module Case(){ ////toplevel 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]) @@ -910,9 +1197,16 @@ module Case(){ ////toplevel HingeScrews(); // catch striker - CatchPortion(catch_width + catch_side_gap*2) + CatchPortion(catch_side_gap*2, epp4[1]) CatchCutProfile(); + // lanyard + Flip_bot(1) + translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]]) + rotate([0, ly_theta, 0]) + rotate([0,0,90]) + LanyardCutout(lanyard_channel_len); + // prop recess Flip_rhs(1) translate([prop_x_pos,0,0]) @@ -933,11 +1227,28 @@ module LidAdhocMultiprintFrame(phase){ } } +module LidAroundEdges(){ + AroundEdges(lpp15[1], lpp13[1] - lpp15[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, -lid_fold_clearance_skew, 0 ], + [ 0, 0, 1, 0 ], + [ 0, 0, 0, 1 ]]) + translate(-skew_centre) + LidAroundEdges() + LidEdgeFoldClearanceProfile(); + } // button covers Buttons(){ @@ -954,10 +1265,13 @@ module Lid(){ ////toplevel } // hinge arms - HingePortion(hex20, hex21) HingeLidProfile(); + HingePortion(hex20, hex21) { + LidEdgeProfile(); + HingeLidProfile(); + } // catch - CatchPortion(catch_width) + CatchPortion(0, lpp12[1]) CatchCatchProfile(); } Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid); @@ -1016,7 +1330,7 @@ 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, lpp13[1], -1); + LidAdhocMultiprintFrame(0); } module LidWindowPrint(){ ////toplevel @@ -1160,7 +1474,7 @@ module TestSelectFrame(){ module TestSelectLidFrame(){ TestSelectFrame(); translate([led_pos[0], -led_pos[1], -50]) - cylinder(r= nla_r2+2, h=100); + cylinder(r= nla_r2+3, h=100); } module TestFrameCase(){ ////toplevel @@ -1174,12 +1488,33 @@ 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(); } } @@ -1254,6 +1589,54 @@ module DemoPropAngles(){ ////toplevel 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(); } @@ -1261,6 +1644,10 @@ module DemoFrame(){ ////toplevel %HingeLever(); } +module DemoLanyardCutout(){ ////toplevel + LanyardCutout(25); +} + module DemoHingedFrame(){ ///toplevel color("red") TestFrameCase(); translate([0,0, -2*hp_k]) @@ -1285,6 +1672,26 @@ module DemoProfiles(){ ////toplevel %EdgeProfile(); KeeperProfile(); translate([0,0,-1]) color("black") KeeperProfile(1); + translate(ly_o){ + rotate(-ly_theta){ + translate([0,0,+1]) color("purple") LanyardMainChannelProfile(); + translate([0,0,+2]) color("red") LanyardCurveChannelProfile(); + translate([0, ly_q_z]){ + translate([0,0,-1]) color("blue") LanyardEntryChannelProfile(); + translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile(); + } + } + } + translate([0,0,-5]) color("white") translate(epp2i) + rotate(-ly_theta) + rectfromto([-15, 0], + [+15, -max_case_bottom_edge_thickness]); + + translate([0,20]) { + LanyardMainChannelProfile(); + translate([0,0,1]) color("purple") LanyardCurveChannelProfile(); + translate([0,0,-1]) color("red") LanyardEntryChannelProfile(); + } translate([20,0]) { LidEdgeProfile();