X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=fcc027ed14b9101e588014ddf7c9a9d989d12d1f;hp=2727880e94f6e24dcd95a60334291a4ebf2ab786;hb=062ada165d5387a09997102172edb523394a7609;hpb=b12d757e8ccab5f791c339f054b3c1a81b241e06 diff --git a/fairphone-case.scad b/fairphone-case.scad index 2727880..fcc027e 100644 --- a/fairphone-case.scad +++ b/fairphone-case.scad @@ -1,5 +1,122 @@ // -*- 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 phone = [ 75.0, 145.0 ]; @@ -14,7 +131,18 @@ bumper = [ 0.250, -0.025 ]; 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; @@ -26,9 +154,13 @@ 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 = [ 13.83, 7.96 ]; +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; @@ -43,10 +175,12 @@ microusb_below = 0.0; 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; @@ -70,20 +204,32 @@ case_lip = 1.25; lid_gap_x = 0.25; lid_gap_z = 0.25; lid_lip = 1.75; +lid_edgepart_width = 5.0; catch_slop = 0.50; 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_nut_dia = 4.72 + 0.50; // washer, actually +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 = 1.93; hingescrew_head_th = 1.38 + 0.75; hingescrew_head_dia = 3.92; + +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; @@ -125,6 +271,8 @@ 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]; @@ -171,7 +319,20 @@ 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]); +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 + + 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 ]; @@ -189,9 +350,22 @@ bppO = [ bppN[0], bppP[1] ]; bppL = lpp10 + [5,0]; bppK = [ bppL[0], bppN[1] ]; bppJ = [ bppN[0], bppL[1] ]; +bppU = [ bppJ[0], lpp12[1] ]; +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_dia/2; +hp_rn = hingescrew_nut_access_dia/2; hp_r2_min = hp_rn + lever_cover_th; hp_rs = hingescrew_shaft_dia/2; hp_r1_min = hp_rs + hingemount_th; @@ -214,19 +388,34 @@ hppE = [ hppE_x, hppE_y ]; // 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 -hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap; -//echo(hex20, hex21, hex22, hex23, hex24); -//echo(hingescrew_portion_len); +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 +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); + +lid_fold_clearance_skew = + (lpp10[1] - hppB[1]) / + (lpp10[0] - hppB[0]); + +echo("SK",lid_fold_clearance_skew); // catch @@ -284,6 +473,26 @@ $prp_r10 = prl_r10; // ---------- modules ---------- +module AdhocMultiprintFrame(phase, z0, zs) { + // from z0 to z0 + zs*layer + extra = phase * (initial_layer_width + multicolour_gap) + 5; + xextra = extra + -epp4[0]; + xrange = [ 0, phone_width ] + [-1,+1] * xextra; + yextra = extra + -epp4[0]; + yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra; + p0 = [ xrange[0], yrange[0] ]; + p1 = [ xrange[1], yrange[1] ]; + echo(p0, p1); + translate([0,0, z0]) + mirror([0,0, zs<0 ? 1 : 0]) + linear_extrude(height= initial_layer_thick) + difference(){ + rectfromto(p0 - [1,1] * initial_layer_width, + p1 + [1,1] * initial_layer_width); + rectfromto(p0, p1); + } +} + module KeeperProfile(slant=0){ use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope; polygon([use_e, kppd, kppc, kppb, kppa, kppf]); @@ -310,7 +519,9 @@ module LidEdgeProfile(){ lpp12, lpp13, lpp13 + [10, 0], - lpp10 + [10, 0] + lpp15 + [10, 0], + lpp15, + lpp14, ]); intersection(){ circleat(lpp12, r=lp_r12); @@ -319,9 +530,22 @@ module LidEdgeProfile(){ } } +module LidEdgeFoldClearanceProfile(){ + translate([-lid_fold_clearance_antislop, 0]) + polygon([ lpp10, + lpp11, + lpp11 + [-20, 0], + lpp11 + [-20, 20], + lpp11 + [+20, 20], + lpp10 + [+20, 0] ]); +} + module ButtonCoverProfile(){ intersection(){ - polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]); + polygon(concat([ bppM, bppP, bppO, bppJ ], + (enable_support && !$button_suppress_over_keeper + ? [ bppU, bppV, bppW ] : []), + [ bppL, bppK ])); hull(){ EdgeProfile(); LidEdgeProfile(); @@ -466,12 +690,13 @@ 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; + $button_suppress_over_keeper= suppress_over_keeper; eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 : y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 : y; @@ -486,9 +711,9 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) { } module Buttons(){ - Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power - Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera - Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume + Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power + Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera + Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume Flip_rhs( ) LidButtonishLeg(14, -1) children(); // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children(); } @@ -584,19 +809,30 @@ module HingeLeverOuterProfile(){ } module HingeLeverInnerProfile(){ - for (c = [hppT, hppB]) { - hull() + for (s = [-1,+1]) { + c = s > 0 ? hppT : hppB; + translate(c) + mirror([0,0,s>0]) + rotate(s<0 ? -40 : 0) + hull() for (x=[-20,20]) - for (y=[0, c[1] - hppM[1]]) + for (y=[0, s * 10]) translate([x,y]) - circleat(c, hp_rn); + circle(hp_rn); + } +} + +module HingeLeverNutProfile(){ + for (c= [hppB, hppT]) { + translate(c) + circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30)); } } -module Flip_hinge(){ +module Flip_hinge(doflip=1){ hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]]; translate(hinge_origin) - rotate([180,0,0]) + rotate([doflip*180,0,0]) translate(-hinge_origin) children(); } @@ -607,7 +843,7 @@ module HingePortion(x0,x1){ mirror([1,0,0]) rotate([90,0,-90]) linear_extrude(height=x1-x0) - children(0); + children(); } module CatchPortion(width){ @@ -781,7 +1017,7 @@ 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]) @@ -832,11 +1068,34 @@ module Case(){ ////toplevel } } +module LidAdhocMultiprintFrame(phase){ + if (led_window_style >= 3) { + AdhocMultiprintFrame(phase, lpp13[1], -1); + } +} + +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(){ @@ -853,7 +1112,10 @@ module Lid(){ ////toplevel } // hinge arms - HingePortion(hex20, hex21) HingeLidProfile(); + HingePortion(hex20, hex21) { + LidEdgeProfile(); + HingeLidProfile(); + } // catch CatchPortion(catch_width) @@ -872,7 +1134,20 @@ module Lid(){ ////toplevel 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 @@ -882,9 +1157,13 @@ module HingeLever(){ ////toplevel HingeLeverOuterProfile(); // space for the screws - HingePortion(hex23, hex24) + HingePortion(hex26, hex24) HingeLeverInnerProfile(); + // recesses for the nuts + HingePortion(hex23, hex26+1) + HingeLeverNutProfile(); + // bores for the screws HingeScrews(); @@ -894,8 +1173,36 @@ 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]) + rotate([-90,0,0]) + translate([-phone_width/2, phone_height, 0]) HingeLever(); } @@ -1013,6 +1320,8 @@ module TestSelectFrame(){ module TestSelectLidFrame(){ TestSelectFrame(); + translate([led_pos[0], -led_pos[1], -50]) + cylinder(r= nla_r2+3, h=100); } module TestFrameCase(){ ////toplevel @@ -1026,12 +1335,33 @@ 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(); } } @@ -1106,6 +1436,54 @@ 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(); } @@ -1125,9 +1503,11 @@ module DemoHingedFrame(){ ///toplevel } 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 @@ -1161,7 +1541,25 @@ module DemoProfiles(){ ////toplevel color("blue") HingeLidProfile(); color("red") HingeBaseProfile(); color("black") translate([0,0,-2]) HingeLeverOuterProfile(); - color("orange") translate([0,0,-1]) HingeLeverInnerProfile(); + } + + for (f=[0,1]) { + translate([-30, -60 + 30*f]) { + translate([0,0,-4]) EdgeProfile(); + %translate([0,0,-10]) HingeBaseProfile(); + translate([0,-2] * f * hp_k) { + translate([0,0,-4]) LidEdgeProfile(); + %translate([0,0,-10]) %HingeLidProfile(); + } + translate(+hppB) rotate([0,0,180*f]) translate(-hppB) { + translate([0,0,-2]) color("black") HingeLeverOuterProfile(); + translate([0,0,0]) color("red") difference(){ + HingeLeverOuterProfile(); + HingeLeverInnerProfile(); + } + translate([0,0,3]) color("yellow") HingeLeverNutProfile(); + } + } } translate([20,-30]) {