5 phone = [ 75.0, 145.0 ];
7 bumper = [ 0.250, -0.025 ];
8 // ^ One side. Overall size is increased by twice this.
9 // If no bumpers, is the gap around the phone.
13 button_cutout_depth = 9;
15 phone_edge_thick = 9.0;
16 phone_total_thick = 12.0;
17 phone_backside_slope_inner = 1.5; // larger means shallower
18 phone_backside_slope_outer = 1.0; // larger means shallower
20 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
21 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
23 jack_pos = [ 13.92, 7.96 ];
24 jack_dia = 9.1 + .5; // some jack I had lying around
26 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
27 noisecancelmic_dia = 1.75;
29 fingerpushhole_dias = [ 15, 18 ];
31 rearspeaker_pos_bl = [ 12.64, 18.72 ];
32 rearspeaker_size = [ 3.76, 7.36 ];
34 microusb_above = 3.27 - 0.25;
36 microusb_width = 16.12 + 0.25;
43 case_struts_count = 6;
44 case_struts_solid_below = 1.00;
45 case_struts_solid_above = 0.75;
46 case_struts_width = 0.10;
50 keeper_inner_width = 2.75;
51 keeper_inner_height = 2.75;
52 keeper_slant_slope = 2; // larger means steeper
54 keeper_gap_z_top = 0.25;
55 keeper_gap_z_bot = 0.75;
57 keeper_gap_x_holes = 0.75;
68 foldover_lever_gap = 0.50;
70 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
71 hingescrew_shaft_len = 12;
72 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
73 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
74 hingescrew_head_th = 1.38 + 0.75;
75 hingescrew_head_dia = 3.92;
76 lever_cover_th = 0.75;
83 buttonishleg_default_l_is_fudge = 10;
85 hinge_base_slope = 1.5; // bigger is steeper
87 strut_min_at_end = 1.5;
90 hinge_x_postscrew_gap = 0.75;
91 hinge_x_arms_gap = 0.35;
92 hinge_r_arms_gap = 0.55;
94 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
98 catch_thickness = 1.0;
99 catch_side_gap = 0.75; // each side
103 catch_finger_height = 1.5;
104 catch_finger_depth = 2.5;
106 // ---------- calculated ----------
108 phone_width = (phone + bumper*2)[0];
109 phone_height = (phone + bumper*2)[1];
111 inside_br = [phone_width, -phone_height];
113 //echo(camera_pos_tl + bumper,
114 // camera_pos_br + bumper);
116 // ----- could be changed -----
117 lid_buttoncover_gap = lid_gap_x;
118 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
120 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
122 //lid_lip_overlap_width xxx bad name = ;
123 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
126 epp1 = [0, -phone_edge_thick];
127 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
128 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
129 epp3 = epp2i + [10, 0];
130 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
131 epp4 = epp5 + [-1,0] * case_th_side;
134 kppd = kppe + [1,0] * keeper_inner_width;
135 kppc = kppd + [0,1] * keeper_th_z;
136 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
137 kppf = kppe - [0,1] * keeper_inner_height;
138 kppa = [ kppb[0], kppf[1] ];
140 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
141 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
143 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
145 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
146 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
150 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
151 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
152 bppS = [ epp1[0], bppR[1] ];
153 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
154 bppP = bppQ + [0,1] * lid_buttoncover_gap;
155 bppO = [ bppN[0], bppP[1] ];
156 bppL = lpp10 + [5,0];
157 bppK = [ bppL[0], bppN[1] ];
158 bppJ = [ bppN[0], bppL[1] ];
161 hp_rn = hingescrew_nut_dia/2;
162 hp_r2_min = hp_rn + lever_cover_th;
163 hp_rs = hingescrew_shaft_dia/2;
164 hp_r1_min = hp_rs + hingemount_th;
166 hp_r1 = max(hp_r1_min, hp_r2_min);
170 hppS = epp2o + [0,-1] * case_th_bottom;
171 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
173 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
174 0.5 * (hppU + hppS)[1] ];
175 hppT = [ hppM[0], hppU[1] - hp_r1 ];
176 hppB = hppT + [0,-1] * hp_k;
178 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
179 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
180 hppE = [ hppE_x, hppE_y ];
182 // hinge elevation x coords
184 hingescrew_portion_len =
185 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
187 hex20 = max(epp2o[0],
189 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
190 hex21 = hex20 + hingescrew_portion_len;
191 hex22 = hex21 + hinge_x_gap;
192 hex23 = hex22 + hingescrew_portion_len
193 - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
194 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
195 echo(hex20, hex21, hex22, hex23, hex24);
196 echo(hingescrew_portion_len);
200 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
201 cppA = cppJ + [lid_gap_x, -lid_gap_z];
202 cppB = [ epp0[0], cppA[1] ];
203 cppP = [ epp4[0], cppJ[1] ];
205 cppS = cppJ + [0,-1] * catch_len;
206 cppD = [ cppA[0], cppS[1] + catch_slop ];
207 cppC = [ cppB[0], cppD[1] ];
208 cppT = cppS + [1,0] * catch_depth;
209 cppU = cppT + [0,-1] * catch_height;
210 cppV = [ cppS[0], cppU[1] - catch_depth ];
212 cppR = 0.5*(cppP + cppJ);
214 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
216 cppV[1] - (catch_finger_height - cp_rQ) ];
217 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
219 // ---------- modules ----------
221 module KeeperProfile(slant=0){
222 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
223 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
226 module EdgeProfile(){
229 translate(epp3) square(case_th_bottom*2, center=true);
230 circleat(epp2o, r=case_th_bottom);
231 circleat(epp1, r=case_th_side);
232 rectfromto(epp0, epp4);
234 polygon([ epp5 + [0,10],
241 module LidEdgeProfile(){
250 circleat(lpp12, r=lp_r12);
251 rectfromto( lpp12 + [-10, 0],
252 lpp12 + [+10, +10] );
256 module ButtonCoverProfile(){
258 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
266 module ButtonPlan(l, deep, cut){
268 (cut ? 0 : lid_buttoncover_gap);
271 (deep ? lid_buttoncover_overlap : 0);
273 C = [0,0]; // by definition
277 B0 = C + [0,-1] * button_cutout_depth;
278 B1 = B0 + [0,1] * epsilon;
280 r0 = 0.5 * (T[1] - B0[1]);
281 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
282 H = A + [0,-1] * delta;
288 E1 = E0 + [1,0] * epsilon;
290 I0 = [ E0[0], H[1] ];
291 I1 = [ E1[0], H[1] ];
294 for (m=[0,1]) mirror([m,0])
295 circleat(H, r0 - epsilon);
297 for (m=[0,1]) mirror([m,0]) {
307 circleat(D, r0 + epsilon);
312 module CatchCatchProfile(){
314 for (c=[ cppR, cppQ ])
318 circleat(lpp12, lp_r12);
319 circleat(lpp12 + [5,0], lp_r12);
320 rectfromto(cppP, cppP + [5,0.1]);
322 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
325 module CatchCutProfile(){
337 module Flip_rhs(yn=[0,1]) {
339 translate([phone_width/2, 0, 0])
340 mirror([$rhsflip,0,0])
341 translate([-phone_width/2, 0, 0])
346 module Flip_bot(yn=[0,1]) {
348 translate([0, -phone_height/2, 0])
349 mirror([0, $botflip, 0])
350 translate([0, phone_height/2, 0])
355 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
358 translate([0, -phone_cnr_rad, 0])
360 linear_extrude(height = phone_height - phone_cnr_rad*2)
364 Flip_rhs() Flip_bot() {
365 translate([+1,-1] * phone_cnr_rad)
370 translate([-1,0] * phone_cnr_rad)
372 rectfromto([0,-20],[10,20]);
374 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
380 translate([ phone_width - phone_cnr_rad, 0,0 ])
382 linear_extrude(height = phone_width - phone_cnr_rad*2)
386 translate([0,0, fill_zstart])
387 mirror([0,0, fill_downwards])
388 linear_extrude(height = fill_th)
389 rectfromto([+1,-1] * phone_cnr_rad,
390 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
393 module CaseAperture(pos, dia, $fn) {
395 translate([ pos[0] + bumper[0],
398 rotate([-90, theta, 0])
399 cylinder(r = dia/2 / cos(theta),
403 module SideButton(y, y_ref_sign, l){
405 // +1 measured from top of actual phone to top of button
406 // -1 measured from bottom of actual phone to bottom of button
407 // 0 y is centre of button in coordinate system
409 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
410 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
413 translate([0, eff_y, 0])
417 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
418 $button_leg_only = true;
419 SideButton(y, y_ref_sign, l) children();
423 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
424 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
425 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
426 Flip_rhs( ) LidButtonishLeg(14, -1) children();
427 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
430 module Struts(x_start, z_min, th){
431 // if th is negative, starts at z_min and works towards -ve z
432 // and object should then be printed other way up
433 for (i= [1 : 1 : case_struts_count]) {
437 mirror([0,0, th<0 ? 1 : 0])
439 -phone_height * i / (case_struts_count+1),
440 case_struts_solid_below])
441 linear_extrude(height= abs(th)
442 -(case_struts_solid_below+case_struts_solid_above))
443 rectfromto([ x_start, -0.5 * case_struts_width ],
444 [ phone_width - x_start, +0.5 * case_struts_width ]);
448 module OrdinaryRearAperture(rhs,bot, pos){
449 Flip_rhs(rhs) Flip_bot(bot)
452 translate(pos + bumper)
460 linextr(-epp2i[0], 60)
461 translate([0.5 * phone_width, 0, 0])
462 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
463 [+microusb_width/2, epp0[1] + -microusb_above]);
467 module OrdinaryRearApertures(){
469 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
470 rectfromto(-rearspeaker_gap,
471 rearspeaker_size + rearspeaker_gap);
473 // finger hole to remove phone
474 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
476 scale(fingerpushhole_dias)
480 module RearCameraAperture(){
483 linear_extrude(height = 20)
486 rectfromto(camera_pos_tl, camera_pos_br);
489 module HingeLidProfile(){
491 circleat(hppT, hp_r1);
492 circleat(lpp12, lp_r12);
500 module HingeBaseProfile(){
503 circleat(hppB, hp_r1);
504 circleat(hppE, hp_r1);
505 circleat(epp2o, case_th_bottom);
506 circleat(hppB + [10,0], hp_r1);
508 polygon([epp5, epp1, epp2i, epp3, bppL]);
512 module HingeLeverOuterProfile(){
514 circleat(hppT, hp_r2);
515 circleat(hppB, hp_r2);
519 module HingeLeverInnerProfile(){
520 for (c = [hppT, hppB]) {
525 circleat(hppB, hp_rn);
530 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
531 translate(hinge_origin)
533 translate(-hinge_origin)
537 module HingePortion(x0,x1){
538 Flip_rhs() Flip_bot(1)
542 linear_extrude(height=x1-x0)
546 module CatchPortion(width){
547 translate([phone_width/2, 0,0])
549 linextr(-width/2, width/2)
554 AroundEdges(epp3[1], case_th_bottom, 1)
558 module Case(){ ////toplevel
563 // ledge (fixed keeper)
566 linear_extrude(height = phone_height + phone_cnr_rad * 2)
569 // outline of the whole case, to stop it protruding
570 translate([0,0, -25])
571 linear_extrude(height = 50)
573 // Flip_rhs() // actually, we only care about the LH
575 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
579 HingePortion(hex20, hex21) HingeBaseProfile();
584 translate([0, -phone_cnr_rad, 0])
586 linear_extrude(height = phone_height + phone_cnr_rad * 2)
589 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
590 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
594 RearCameraAperture();
596 // struts (invisible, because they're buried in the case)
597 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
604 linear_extrude(height= 20)
605 ButtonPlan($button_l, 0,1);
606 if ($button_leg_only)
608 translate([phone_width/2, -400, kppe[1]])
609 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
611 translate([0,0, -bppR[0]])
612 linear_extrude(height= 20)
613 ButtonPlan($button_l, 1,1);
617 // apertures along top edge
618 CaseAperture(jack_pos, jack_dia, 8);
620 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
622 OrdinaryRearApertures();
626 // gaps for the lid's hinge arms
627 HingePortion(hex20 - hinge_x_arms_gap,
628 hex21 + hinge_x_arms_gap)
631 circle(r= hinge_r_arms_gap, $fn= 8);
634 // screw holes in the hinge arms
638 CatchPortion(catch_width + catch_side_gap*2)
643 module Lid(){ ////toplevel
646 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
654 linear_extrude(height= 20)
655 ButtonPlan($button_l, 1,0);
657 translate([0,0,-100])
658 linear_extrude(height= 200)
659 ButtonCoverProfile();
664 HingePortion(hex20, hex21) HingeLidProfile();
667 CatchPortion(catch_width)
670 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
672 // screw holes in the hinge arms
677 module HingeLever(){ ////toplevel
679 // outer body, positive
680 HingePortion(hex22, hex22 + phone_width/2)
681 HingeLeverOuterProfile();
683 // space for the screws
684 HingePortion(hex23, hex24)
685 HingeLeverInnerProfile();
687 // bores for the screws
690 // space for the charging cable
692 Flip_hinge() MicroUSB();
696 module HingeLeverPrint(){ ////toplevel
701 module TestSelectLength(){
702 translate([-30, -200, -20])
703 cube([30 + 15, 250, 40]);
706 module TestLength(){ ////toplevel
713 module TestLengthRight(){ ////toplevel
721 module TestSelectWidth(){
722 translate([-30, -(phone_height - 25), -20])
727 module TestWidth(){ ////toplevel
734 module TestLidWidthPrint(){ ////toplevel
735 rotate([0,180.0]) intersection(){
741 module TestSelectRearAperture(){
745 cube([42, 2, 1], center=true);
749 module TestSelectCamera(){
751 TestSelectRearAperture()
752 RearCameraAperture();
753 cube([0.1, 50, 0.1]);
757 module TestSelectOrdinaryRearApertures(){
758 TestSelectRearAperture()
759 OrdinaryRearApertures();
762 module TestCamera(){ ////toplevel
769 module TestLidByCamera(){ ////toplevel
776 module TestLidByCameraPrint(){ ////toplevel
777 rotate([180,0,0]) TestLidByCamera();
780 module DemoByCamera(){ ////toplevel
781 color("blue") TestLidByCamera();
782 color("red") TestCamera();
785 module OneKeeper(){ ////toplevel
786 translate([0, -phone_cnr_rad, 0])
788 linear_extrude(height = phone_height - phone_cnr_rad * 2)
792 module OneKeeperPrint(){ ////toplevel
797 module LidPrint(){ ////toplevel
802 module TestSelectFrame(){
803 include = [1,-1] * (epp2i[0] + 4);
806 cube(1000, center=true);
807 translate([0,0, -100])
808 linear_extrude(height=200)
809 rectfromto(include, inside_br - include);
813 module TestFrameCase(){ ////toplevel
819 TestSelectOrdinaryRearApertures();
824 module TestFrameLidPrint(){ ////toplevel
825 rotate([0,180,0]) intersection(){
831 module Keeper(){ ////toplevel
836 module ButtonPlanForDemo(z, deep, cut){
838 ButtonPlan(8, deep, cut);
841 module HingeScrews(){
842 Flip_rhs() Flip_bot(1){
843 for (c= [ hppT, hppB ])
849 cylinder( r= hingescrew_shaft_dia/2,
850 h = hingescrew_shaft_len+0.2 );
853 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
858 module DemoFrame(){ ////toplevel
859 color("red") TestFrameCase();
860 color("blue") intersection(){ Lid(); TestSelectFrame(); }
861 color("black") HingeScrews();
865 module DemoHingedFrame(){ ///toplevel
866 color("red") TestFrameCase();
867 translate([0,0, -2*hp_k])
868 color("blue") intersection(){ Lid(); TestSelectFrame(); }
871 color("orange") HingeLever();
872 color("black") HingeScrews();
876 module DemoHinge(){ ////toplevel
878 translate([0,0, -hp_k*3])
882 module DemoProfiles(){ ////toplevel
886 translate([0,0,-1]) color("black") KeeperProfile(1);
892 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
894 color("blue") ButtonCoverProfile();
896 rectfromto(bppQ, demopoint_QR);
897 rectfromto(bppR, demopoint_QR);
902 color("black") ButtonPlanForDemo(-2, 0,1);
903 color("red" ) ButtonPlanForDemo(-4, 1,1);
904 color("blue") ButtonPlanForDemo(-6, 1,0);
907 translate([0, -30]) {
910 color("blue") HingeLidProfile();
911 color("red") HingeBaseProfile();
912 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
913 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
916 translate([20,-30]) {
919 //translate([0,0,1]) CatchCutProfile();
920 color("blue") CatchCatchProfile();
921 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }