X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=ea8207e48131d06037b39d88fb29ac1875d013fd;hp=a4d07f3895ad22d331284fd6d7d9a66379372cbe;hb=fcf81b2e44a44a2d818c4782ddee1ce10d2c0c2f;hpb=05a844f3521ba8ac26be435bc93d4588cfc71a0c diff --git a/fairphone-case.scad b/fairphone-case.scad index a4d07f3..ea8207e 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,7 +1,12 @@ // -*- C -*- -phone_height = 146.5; -phone_width = 76.75; +include + +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; @@ -12,12 +17,23 @@ phone_total_thick = 12.0; 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 +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; -case_th_bottom = 3.5; -case_th_lid = 3.5; -case_th_side = 2.5; +fingerpushhole_dias = [ 14, 17 ]; + +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_struts_count = 6; @@ -42,15 +58,42 @@ 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; -button_l_fudge = 4.5; +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; @@ -83,8 +126,6 @@ lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]); lpp12 = [ epp4[0] + lp_r12, lpp11[1] ]; lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ]; -echo(lpp13 - lpp10); - // button profile bppM = epp4 + [0,5]; bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ]; @@ -97,12 +138,35 @@ bppL = lpp10 + [5,0]; bppK = [ bppL[0], bppN[1] ]; bppJ = [ bppN[0], bppL[1] ]; -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); } +// 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; @@ -161,6 +225,8 @@ module ButtonPlan(l, deep, cut){ 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; @@ -183,7 +249,7 @@ module ButtonPlan(l, deep, cut){ polygon([ E1, I1, H, - B0, + B1, G, F, D @@ -193,19 +259,19 @@ module ButtonPlan(l, deep, cut){ } } -module CaseBase_rhsflip(yn=[0,1]) { - for (rhs=yn) { +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(); } @@ -213,14 +279,14 @@ module CaseBase_botflip() { module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ // sides - CaseBase_rhsflip(){ + Flip_rhs(){ translate([0, -phone_cnr_rad, 0]) rotate([90,0,0]) linear_extrude(height = phone_height - phone_cnr_rad*2) children(0); } // corners - CaseBase_rhsflip() CaseBase_botflip() { + Flip_rhs() Flip_bot() { translate([+1,-1] * phone_cnr_rad) intersection(){ rotate_extrude() @@ -235,7 +301,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ } } // top and bottom - CaseBase_botflip(){ + Flip_bot(){ translate([ phone_width - phone_cnr_rad, 0,0 ]) rotate([90,0,-90]) linear_extrude(height = phone_width - phone_cnr_rad*2) @@ -249,16 +315,41 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){ [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad); } -module SideButton(y,l){ +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; - translate([0, -y, 0]) - mirror([1,0,0]) - rotate([90,0,90]) + 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(){ - CaseBase_rhsflip([1]) SideButton(20.6, 8.8) children(); // power + 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){ @@ -279,6 +370,84 @@ module Struts(x_start, z_min, th){ } } +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(); @@ -299,14 +468,17 @@ module Case(){ ////toplevel translate([0,0, -25]) linear_extrude(height = 50) hull() - // CaseBase_rhsflip() // actually, we only care about the LH - CaseBase_botflip() + // 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 - CaseBase_rhsflip(1) + Flip_rhs(1) translate([0, -phone_cnr_rad, 0]) rotate([90, 0, 0]) linear_extrude(height = phone_height + phone_cnr_rad * 2) @@ -317,23 +489,43 @@ module Case(){ ////toplevel } // front camera - CaseBase_rhsflip([1]) - mirror([0, 0, 1]) - linear_extrude(height = 20) - mirror([0, 1, 0]) - rectfromto(camera_pos_tl, camera_pos_br); + RearCameraAperture(); // struts (invisible, because they're buried in the case) Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom); Buttons(){ - translate([0,0,-10]) - linear_extrude(height= 20) - ButtonPlan($button_l, 0,1); - translate([0,0, -bppR[0]]) - linear_extrude(height= 20) - ButtonPlan($button_l, 1,1); + mirror([1,0,0]) + rotate([90,0,90]) { + intersection(){ + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($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, $fn= 8); + } } } @@ -342,50 +534,112 @@ module Lid(){ ////toplevel union(){ AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0) LidEdgeProfile(); + + // button covers + Buttons(){ + intersection(){ + rotate([90,0,90]) + translate([0,0,-10]) + linear_extrude(height= 20) + ButtonPlan($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(); - translate([-30, -200, -20]) - cube([30 + 15, 250, 40]); + 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(); - translate([-30, -(phone_height - 25), -20]) - mirror([0, 1, 0]) - cube([200, 50, 40]); + TestSelectWidth(); } } module TestLidWidthPrint(){ ////toplevel - rotate([0,180.0]) - intersection(){ - Lid(); - translate([-30, -(phone_height - 25), -20]) - mirror([0, 1, 0]) - cube([200, 50, 40]); - } + 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(); - CaseBase_rhsflip(1) - translate([0,0,-25]) - linear_extrude(height = 50) - mirror([0, 1, 0]) - rectfromto([-20, -20], - camera_pos_br + [ 5, 5 ]); + 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]) @@ -398,8 +652,42 @@ module OneKeeperPrint(){ ////toplevel 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 - CaseBase_rhsflip() + Flip_rhs() OneKeeper(); } @@ -408,6 +696,11 @@ module ButtonPlanForDemo(z, deep, cut){ ButtonPlan(8, deep, cut); } +module DemoFrame(){ ////toplevel + color("red") TestFrameCase(); + color("blue") intersection(){ Lid(); TestSelectFrame(); } +} + module DemoProfiles(){ ////toplevel LidEdgeProfile(); %EdgeProfile(); @@ -432,6 +725,15 @@ module DemoProfiles(){ ////toplevel 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();