3 // Hard case for Fairphone 2
5 // Copyright 2018 Ian Jackson. There is NO WARRANTY.
6 // See below for full licensing and disclaimer.
10 // 1. You will want to git clone this repository.
12 // 2. Decide about the notification LED aperture. See the variable
13 // led_window_style, below. The default here is "ad-hoc
14 // multi-colour", which can produces a translucent (clear-ish)
15 // window set into the lid, even on a single-nozzle printer.
16 // See "Ad-hoc multi-colour", below.
18 // 3. use "make" to generate the necessary files:
20 // make -j8 fairphone-case.auto.scads `for f in \
26 // ; do echo fairphone-case,$f.auto.stl; done`
28 // 4. Print them. Case and OneKeeperPrint should probably be
31 // For Lid and LidWindowPrint, if you are doing ad-hoc
33 // i. Set up for clear filament
34 // ii. Print LidWindowPrint. Wait for it to finish.
35 // It won't take long. As soon as it finishes, tell
36 // your printer to warm up (so that in fact it does
38 // iii. Leaving the output so far on the printbed, reload
39 // your printer with the main lid colour.
40 // iv. Print LidPrint. You can let this go unattended.
42 // 5. Assemble the hinge. You will need 4x M2 12mm machine screws
43 // and 8x M2 full nuts.
45 // Make sure you get the hinge the right way round. If you're not
47 // openscad fairphone-case,DemoHinge.auto.scad
48 // to see an assembly diagram.
50 // The nuts recess into the hinge. You will want very fine
51 // pliers. As you screw each screw in, add the second nut when
52 // the screw thread emerges from the first - this will be a
53 // locknut. Screw each screw to an appropriate tightness for the
54 // hinge stiffness. You want the lid-side hinge to be stiffer as
55 // that makes closing the case work better.
57 // When you have the stiffness right, tighten the locknuts onto
62 // - To put the phone in, drop its RH side into the RH side of
63 // the case. Then feed the keeper through the small hole.
64 // Feed it right through.
66 // - The optional prop can be used to prop the phone up (in
67 // portrait orientation only right now). See
68 // openscad fairphone-case,DemoPropAngles.auto.scad
70 // Ad-hoc multi-colour
72 // This file is set up to let you make a translucent window using a
73 // single-extruder printer, using a "two print run" technique. This
74 // works well with our Lulzbot TAZ 5 and Aleph Objects' version of
75 // Cura. If you are using a different printer, you may need to
76 // adjust the parameters or try a different technique. In particular,
77 // initial_layer_thick
78 // set so that the window is one layer thick
79 // initial_layer_width
80 // set so that the slicer draws a rectangle around the whole
81 // object, rather than putting a "skirt" or anything inside
83 // If you have a dual-extruder printer, you can set led_window_style
84 // to 2 and do a single print of LidPrint and LidWindowPrint.
86 // Alternatively you can set it to 1 (just a hole) or 0 (no hole).
88 // Thanks to Clare Boothby for the ad-hoc multi-colour technique (and
89 // the parameters for our Lulzbot TAZ 5 and Aleph Objects's Cura).
93 // It might well be possible to adapt this file for other phones.
94 // If you do, let me know how you get on.
97 // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY
99 // Copyright (C)2018 Ian Jackson.
101 // This program for generating a 3D model is free software: you can
102 // redistribute it and/or modify it under the terms of the GNU
103 // General Public License as published by the Free Software
104 // Foundation, either version 3 of the License, or (at your option)
105 // any later version.
107 // This program is distributed in the hope that it will be useful,
108 // but WITHOUT ANY WARRANTY; without even the implied warranty of
109 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
110 // GNU General Public License for more details.
112 // You should have received a copy of the GNU General Public
113 // License along with this program. If not, see
114 // <http://www.gnu.org/licenses/>.
116 // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY
117 // PROTECT YOUR PHONE ! It is your responsibility to decide whether
118 // this case will meet your needs.
123 phone = [ 75.0, 145.0 ];
125 prop_buildout_less = 3;
127 prop_angles = [ 15, 30, 45, 60 ];
129 bumper = [ 0.250, -0.025 ];
130 // ^ One side. Overall size is increased by twice this.
131 // If no bumpers, is the gap around the phone.
135 led_window_style = 3;
137 // 1: simply an opening
138 // 2: opening with separate cover model, for printing in clear (two colour)
139 // 3: like 2 but one-layer window for ad-hoc multi-colour
141 initial_layer_thick = 0.400; // ^ needed for mode 3 only
142 initial_layer_width = 0.750; // ^ needed for mode 3 only
143 multicolour_gap = 0.15; // each side
146 phone_rim_depth = 0.80; // includes allowance for a screen protector
148 button_cutout_depth = 9;
150 phone_edge_thick = 9.0;
151 phone_total_thick = 12.0;
152 phone_backside_slope_inner = 1.5; // larger means shallower
153 phone_backside_slope_outer = 1.0; // larger means shallower
155 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
156 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
158 jack_pos = [ 13.83, 8.485 ];
159 jack_dia = 10.64 + .5; // some jack I had lying around
161 led_pos = [ 13.98, 10.00 ];
163 led_window_ledge = 0.75; // each side
165 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
166 noisecancelmic_dia = 4.00;
168 //fingerpushhole_dias = [ 15, 18 ];
169 fingerpushhole_dias = [];
171 lanyard_half_dia = 1.15;
173 rearspeaker_pos_bl = [ 12.64, 18.72 ];
174 rearspeaker_size = [ 3.76, 7.36 ];
176 microusb_above = 3.27 - 0.25;
177 microusb_below = 0.0;
178 microusb_width = 16.12 + 1.25;
180 case_th_bottom = 2.5;
185 lid_screen_gap_extra = .66;
187 case_struts_count = 6;
188 case_struts_solid_below = 1.00;
189 case_struts_solid_above = 0.75;
190 case_struts_width = 0.10;
194 keeper_inner_width = 2.75;
195 keeper_inner_height = 2.75;
196 keeper_slant_slope = 2; // larger means steeper
198 keeper_gap_z_top = 0.25;
199 keeper_gap_z_bot = 0.75;
201 keeper_gap_x_holes = 0.75;
203 keeper_side = 0; // 0 = lhs; 1 = rhs
210 lid_edgepart_width = 5.0;
211 lid_buttoncover_thick = 1.3;
216 foldover_lever_gap = 0.50;
218 // properties of the hinge fasteners
219 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
220 hingescrew_shaft_len = 12;
221 hingescrew_fasteners_extra_thick = 0.40;
222 // ^ amount of thread protruding if everything was completely nominal
223 // and we are using two nuts
224 hingescrew_nut_access_dia = 4.72 + 0.50;
225 // ^ washer is 4.72 dia
226 // also, want to get pliers or tiny spanner in to do up locknut
227 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
228 hingescrew_nut_thick = 1.93;
229 hingescrew_head_th = 1.38 + 0.75;
230 hingescrew_head_dia = 3.92;
232 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
234 lever_cover_th = 0.75;
236 hingemount_wd = 4.8725;
241 button_l_fudge = 4.4;
242 buttonishleg_default_l_is_fudge = 10;
244 hinge_base_slope = 1.5; // bigger is steeper
246 strut_min_at_end = 1.5;
249 hinge_x_postscrew_gap = 0.75;
250 hinge_x_arms_gap = 0.35;
251 hinge_r_arms_gap = 0.55;
253 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
257 catch_thickness = 1.0;
258 catch_side_gap = 0.75; // each side
262 catch_finger_height = 1.5;
263 catch_finger_depth = 2.5;
265 catch_topcurve_r = 5.0;
267 prop_recess_under = 0.50;
268 prop_recess_slop = 0.200; // each side
273 prop_side_gap = 0.75; // each side
274 prop_lidrecess_behind = 0.75;
275 prop_caserecess_behind = 0.75;
276 prop_caserecess_taper = 0.45; // one side only
278 prop_prong_heel_slope = 0.5;
280 lid_fold_clearance_antislop = 0.5;
282 // ---------- calculated ----------
284 phone_width = (phone + bumper*2)[0];
285 phone_height = (phone + bumper*2)[1];
287 inside_br = [phone_width, -phone_height];
289 prop_prong_h = prop_main_th;
291 //echo(camera_pos_tl + bumper,
292 // camera_pos_br + bumper);
294 // ----- could be changed -----
295 lid_buttoncover_gap = lid_gap_x;
296 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
298 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
300 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
302 //prop_nose_len = case_th_lid - prop_recess_under;
303 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
304 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
307 //lid_lip_overlap_width xxx bad name = ;
308 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
311 epp1 = [0, -phone_edge_thick];
312 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
313 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
314 epp3 = epp2i + [10, 0];
315 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
316 epp4 = epp5 + [-1,0] * case_th_side;
319 kppd = kppe + [1,0] * keeper_inner_width;
320 kppc = kppd + [0,1] * keeper_th_z;
321 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
322 kppf = kppe - [0,1] * keeper_inner_height;
323 kppa = [ kppb[0], kppf[1] ];
325 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
326 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
328 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
329 // exact x posn not very important; must extend past end of keeper
332 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
333 + lid_screen_gap_extra ];
334 // ^ beam theory says to maximise force before contact,
335 // the gap below the `beam' (the lid) must be 1/3
336 // the thickness (ie the lid thickness) if the beam
337 // is solid, or 1/2 if it has a top and bottom only.
338 // ours is mostly solid.
340 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
343 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
344 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
346 case_bottom_z = epp2o[1] - case_th_bottom;
350 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
351 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
352 bppS = [ epp1[0], bppR[1] ];
353 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
354 bppP = bppQ + [0,1] * lid_buttoncover_gap;
355 bppO = [ bppN[0], bppP[1] ];
356 bppL = lpp10 + [5,0];
357 bppK = [ bppL[0], bppN[1] ];
358 bppJ = [ bppN[0], bppL[1] ];
359 bppU = [ bppJ[0], lpp12[1] ];
363 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
365 // notification led aperture
367 nla_r0 = led_aperture/2;
368 nla_r1 = nla_r0 + led_window_ledge;
369 nla_r2 = nla_r1 + multicolour_gap;
371 led_window_style >= 3 ? initial_layer_thick :
372 led_window_style >= 2 ? led_window_ledge : 0;
376 hp_rn = hingescrew_nut_access_dia/2;
377 hp_r2_min = hp_rn + lever_cover_th;
378 hp_rs = hingescrew_shaft_dia/2;
379 hp_r1_min = hp_rs + hingemount_th;
381 hp_r1 = max(hp_r1_min, hp_r2_min);
385 hppS = epp2o + [0,-1] * case_th_bottom;
386 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
388 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
389 0.5 * (hppU + hppS)[1] ];
390 hppT = [ hppM[0], hppU[1] - hp_r1 ];
391 hppB = hppT + [0,-1] * hp_k;
393 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
394 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
395 hppE = [ hppE_x, hppE_y ];
397 // hinge elevation x coords
399 hex20 = max(epp2o[0],
401 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
402 hex21 = hex20 + hingemount_wd;
403 hex22 = hex21 + hinge_x_gap;
404 hex27 = hex20 + hingescrew_shaft_len;
405 hex24 = hex27 + hinge_x_postscrew_gap;
406 hex23 = hex27 - (hingescrew_nut_thick*2
407 + hingescrew_fasteners_extra_thick);
408 hex26 = hex23 + hingescrew_nut_thick * 2/3;
410 echo(hex20, hex21, hex22, hex23, hex24);
411 // 6, 10.8725, 10.9975, 13.74, 18.75
412 module chk(act,exp) {
413 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
414 else echo("ok", act);
422 lid_fold_clearance_skew =
423 (lpp10[1] - hppB[1]) /
424 (lpp10[0] - hppB[0]);
426 echo("SK",lid_fold_clearance_skew);
430 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
431 cppA = cppJ + [lid_gap_x, -lid_gap_z];
432 cppB = [ epp0[0], cppA[1] ];
433 cppP = [ epp4[0], cppJ[1] ];
435 cppS = cppJ + [0,-1] * catch_len;
436 cppD = [ cppA[0], cppS[1] + catch_slop ];
437 cppC = [ cppB[0], cppD[1] ];
438 cppT = cppS + [1,0] * catch_depth;
439 cppU = cppT + [0,-1] * catch_height;
440 cppV = [ cppS[0], cppU[1] - catch_depth ];
442 cppR = 0.5*(cppP + cppJ);
444 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
446 cppV[1] - (catch_finger_height - cp_rQ) ];
447 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
451 ly_r = lanyard_half_dia / 2;
454 // prop recess in case
456 prop_x_pos = phone_width/2;
458 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
460 prc_r1 = prop_end_dia/2;
461 prc_r3 = prc_r1 + prop_recess_slop;
463 prcp2 = [ epp4[0] + prop_buildout_less,
466 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
468 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
469 epp2i[1] - prc_r3 - prop_recess_under];
471 // prop recess in lid
473 prl_r10 = prop_end_dia/2;
474 prl_r10o = prl_r10 + prop_recess_slop;
476 prlp10 = lpp10 + [1,1] * prl_r10o
477 + [1,0] * prop_lidrecess_behind
478 + [0,1] * prop_recess_under;
483 $prpp11 = [0, prop_taper_len];
487 // ---------- modules ----------
489 module AdhocMultiprintFrame(phase, z0, zs) {
490 // from z0 to z0 + zs*layer
491 extra = phase * (initial_layer_width + multicolour_gap) + 5;
492 xextra = extra + -epp4[0];
493 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
494 yextra = extra + -epp4[0];
495 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
496 p0 = [ xrange[0], yrange[0] ];
497 p1 = [ xrange[1], yrange[1] ];
500 mirror([0,0, zs<0 ? 1 : 0])
501 linear_extrude(height= initial_layer_thick)
503 rectfromto(p0 - [1,1] * initial_layer_width,
504 p1 + [1,1] * initial_layer_width);
509 module KeeperProfile(slant=0){
510 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
511 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
514 module EdgeProfile(){
517 translate(epp3) square(case_th_bottom*2, center=true);
518 circleat(epp2o, r=case_th_bottom);
519 circleat(epp1, r=case_th_side);
520 rectfromto(epp0, epp4);
522 polygon([ epp5 + [0,10],
529 module LanyardLanyardProfile(entry=false){
531 for (xs=[-1,+1] * (entry ? 2 : 1))
532 translate(xs * 0.5 * lanyard_half_dia * [1,0])
533 circle(r= lanyard_half_dia/2);
537 module LanyardCurveChannelProfile(){
538 translate([0, -ly_r])
539 LanyardLanyardProfile();
542 module LanyardEntryChannelProfile(){
543 translate([0, -ly_r])
544 LanyardLanyardProfile(true);
547 module LanyardMainChannelProfile(){
548 LanyardCurveChannelProfile();
550 square(center=true, ly_r * [6, 2]);
552 translate(ly_r * [3 * xs, -1])
557 module LanyardEntry(){
560 translate([0, ly_rc + ly_r])
561 LanyardCurveChannelProfile();
564 module LanyardCutout(){
568 module LidEdgeProfile(){
579 circleat(lpp12, r=lp_r12);
580 rectfromto( lpp12 + [-10, 0],
581 lpp12 + [+10, +10] );
585 module LidEdgeFoldClearanceProfile(){
586 translate([-lid_fold_clearance_antislop, 0])
595 module ButtonCoverProfile(){
597 polygon(concat([ bppM, bppP, bppO, bppJ ],
598 (enable_support && !$button_suppress_over_keeper
599 ? [ bppU, bppV, bppW ] : []),
608 module ButtonPlan(l, deep, cut){
610 (cut ? 0 : lid_buttoncover_gap);
613 (deep ? lid_buttoncover_overlap : 0);
615 C = [0,0]; // by definition
619 B0 = C + [0,-1] * button_cutout_depth;
620 B1 = B0 + [0,1] * epsilon;
622 r0 = 0.5 * (T[1] - B0[1]);
623 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
624 H = A + [0,-1] * delta;
630 E1 = E0 + [1,0] * epsilon;
632 I0 = [ E0[0], H[1] ];
633 I1 = [ E1[0], H[1] ];
636 for (m=[0,1]) mirror([m,0])
637 circleat(H, r0 - epsilon);
639 for (m=[0,1]) mirror([m,0]) {
649 circleat(D, r0 + epsilon);
654 module CatchCatchProfile(){
656 for (c=[ cppR, cppQ ])
660 circleat(lpp12, lp_r12);
661 circleat(lpp12 + [5,0], lp_r12);
662 rectfromto(cppP, cppP + [5,0.1]);
664 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
667 module CatchCutProfile(){
679 module Flip_rhs(yn=[0,1]) {
681 translate([phone_width/2, 0, 0])
682 mirror([$rhsflip,0,0])
683 translate([-phone_width/2, 0, 0])
688 module Flip_bot(yn=[0,1]) {
690 translate([0, -phone_height/2, 0])
691 mirror([0, $botflip, 0])
692 translate([0, phone_height/2, 0])
697 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
700 translate([0, -phone_cnr_rad, 0])
702 linear_extrude(height = phone_height - phone_cnr_rad*2)
706 Flip_rhs() Flip_bot() {
707 translate([+1,-1] * phone_cnr_rad)
712 translate([-1,0] * phone_cnr_rad)
714 rectfromto([0,-20],[10,20]);
716 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
722 translate([ phone_width - phone_cnr_rad, 0,0 ])
724 linear_extrude(height = phone_width - phone_cnr_rad*2)
728 translate([0,0, fill_zstart])
729 mirror([0,0, fill_downwards])
730 linear_extrude(height = fill_th)
731 rectfromto([+1,-1] * phone_cnr_rad,
732 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
735 module CaseAperture(pos, dia, $fn) {
737 translate([ pos[0] + bumper[0],
740 rotate([-90, theta, 0])
741 cylinder(r = dia/2 / cos(theta),
745 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
747 // +1 measured from top of actual phone to top of button
748 // -1 measured from bottom of actual phone to bottom of button
749 // 0 y is centre of button in coordinate system
751 $button_suppress_over_keeper= suppress_over_keeper;
752 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
753 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
756 translate([0, eff_y, 0])
760 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
761 $button_leg_only = true;
762 SideButton(y, y_ref_sign, l) children();
766 Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
767 Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
768 Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
769 Flip_rhs( ) LidButtonishLeg(14, -1) children();
770 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
773 module Struts(x_start, z_min, th){
774 // if th is negative, starts at z_min and works towards -ve z
775 // and object should then be printed other way up
776 for (i= [1 : 1 : case_struts_count]) {
780 mirror([0,0, th<0 ? 1 : 0])
782 -phone_height * i / (case_struts_count+1),
783 case_struts_solid_below])
784 linear_extrude(height= abs(th)
785 -(case_struts_solid_below+case_struts_solid_above))
786 rectfromto([ x_start, -0.5 * case_struts_width ],
787 [ phone_width - x_start, +0.5 * case_struts_width ]);
791 module OrdinaryRearAperture(rhs,bot, pos){
792 Flip_rhs(rhs) Flip_bot(bot)
795 translate(pos + bumper)
803 linextr(-epp2i[0], 60)
804 translate([0.5 * phone_width, 0, 0])
805 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
806 [+microusb_width/2, epp0[1] + -microusb_above]);
810 module OrdinaryRearApertures(){
812 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
813 rectfromto(-rearspeaker_gap,
814 rearspeaker_size + rearspeaker_gap);
816 // finger hole to remove phone
817 if (len(fingerpushhole_dias))
818 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
820 scale(fingerpushhole_dias)
824 module RearCameraAperture(){
827 linear_extrude(height = 20)
830 rectfromto(camera_pos_tl, camera_pos_br);
833 module HingeLidProfile(){
835 circleat(hppT, hp_r1);
836 circleat(lpp12, lp_r12);
844 module HingeBaseProfile(){
847 circleat(hppB, hp_r1);
848 circleat(hppE, hp_r1);
849 circleat(epp2o, case_th_bottom);
850 circleat(hppB + [10,0], hp_r1);
852 polygon([epp5, epp1, epp2i, epp3, bppL]);
856 module HingeLeverOuterProfile(){
858 circleat(hppT, hp_r2);
859 circleat(hppB, hp_r2);
863 module HingeLeverInnerProfile(){
865 c = s > 0 ? hppT : hppB;
868 rotate(s<0 ? -40 : 0)
877 module HingeLeverNutProfile(){
878 for (c= [hppB, hppT]) {
880 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
884 module Flip_hinge(doflip=1){
885 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
886 translate(hinge_origin)
887 rotate([doflip*180,0,0])
888 translate(-hinge_origin)
892 module HingePortion(x0,x1){
893 Flip_rhs() Flip_bot(1)
897 linear_extrude(height=x1-x0)
901 module CatchPortion(xwidth, ztop){
902 width = catch_width + xwidth;
903 w = width + catch_topcurve_r*2 + 1;
904 translate([phone_width/2, 0,0]){
909 translate([0, 50, 0])
911 linear_extrude(height=100){
912 for (m=[0,1]) mirror([m,0,0]) {
914 translate([w/2, ztop - catch_topcurve_r])
915 circle(catch_topcurve_r);
916 translate([w/2, -50])
917 square(catch_topcurve_r*2, center=true);
926 AroundEdges(epp3[1], case_th_bottom, 1)
930 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
932 module PropProfileAssignments(gamma){
933 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
935 p = phone_height + prlp10[0] - hppB[0];
938 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
940 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
941 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
943 $prp_theta = 90 - $prp_alpha;
944 beta = 180 - $prp_alpha - gamma;
947 //echo("abc", a,b,c);
949 v1 = [ [ cos(psi), -sin(psi) ], // x
950 [ sin(psi), cos(psi) ] ]; // y
952 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
955 $prp_r11 = prop_main_th/2;
957 $prpp1 = $prpp7 + [1,0] *
958 // this is approximate, but will do
959 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
962 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
963 $prpp12 = $prpp3 + v1[0] *
964 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
965 $prp_r8 = prop_main_th;
966 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
968 $prpp5 = [ $prpp12[0] - $prp_r5,
969 $prpp3[1] - prop_prong_h + $prp_r5 ];
970 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
971 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
972 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
973 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
978 module PropProfile(gamma, cut=0, rot=0){ ////toplevel
979 PropProfileAssignments(gamma){
981 //#circleat($prpp3,1);
982 //#circleat($prpp12,1);
989 polygon([[-20,-0], [20,20], [0,0]]);
991 rectfromto($prpp6, $prpp9);
992 translate($prpp5) intersection(){
994 polygon([[-10,-10], [0,0], [10,0]]);
996 rectfromto($prpp12 + [0,-0.1], $prpp3);
999 circleat($prpp1, $prp_r1);
1000 rectfromto($prpp12 + [0,-0.1], $prpp3);
1004 rotate([0,0, rot*-$prp_theta]){
1006 extra = cut ? prop_recess_slop : 0;
1007 rectfromto($prpp6, $prpp9);
1008 circleat($prpp11, $prp_r11 + extra);
1009 circleat($prpp10, $prp_r10 + extra);
1015 module PropAggregateProfile(){
1016 for (angle = prop_angles)
1017 PropProfile(angle, 0,0);
1020 module Prop(){ ////toplevel
1021 hw = prop_main_width/2;
1023 PropAggregateProfile();
1026 module Case(){ ////toplevel
1031 // ledge (fixed keeper)
1032 Flip_rhs(1-keeper_side) intersection(){
1034 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1037 // outline of the whole case, to stop it protruding
1038 translate([0,0, -25])
1039 linear_extrude(height = 50)
1042 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1046 HingePortion(hex20, hex21) HingeBaseProfile();
1048 // buildout for prop recess
1049 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1050 linextr(case_bottom_z, epp2i[1])
1053 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1055 r = epp2o[0] - prcp2[0]);
1060 Flip_rhs(keeper_side)
1061 translate([0, -phone_cnr_rad, 0])
1063 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1066 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1067 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1071 RearCameraAperture();
1073 // struts (invisible, because they're buried in the case)
1074 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1079 if (!($button_leg_only && enable_support))
1081 translate([0,0,-10])
1082 linear_extrude(height= 20)
1083 ButtonPlan($button_l, 0,1);
1084 if ($button_leg_only)
1086 translate([phone_width/2, -400, kppe[1]])
1087 mirror([1-abs($rhsflip - keeper_side),0,0])
1088 cube([400, 800, 50]);
1089 if (enable_support && !$button_suppress_over_keeper)
1091 translate([-400, -400, kppd[1]])
1093 cube([800,800,100]);
1095 translate([0,0, -bppR[0]])
1096 linear_extrude(height= 20)
1097 ButtonPlan($button_l, 1,1);
1102 // apertures along top edge
1103 CaseAperture(jack_pos, jack_dia, 8);
1105 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1107 OrdinaryRearApertures();
1111 // gaps for the lid's hinge arms
1112 HingePortion(hex20 - hinge_x_arms_gap,
1113 hex21 + hinge_x_arms_gap)
1116 circle(r= hinge_r_arms_gap, $fn= 8);
1119 // screw holes in the hinge arms
1123 CatchPortion(catch_side_gap*2, epp4[1])
1128 translate([prop_x_pos,0,0])
1131 linextr(-prop_recess_hw, +prop_recess_hw)
1133 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1134 circleat(prcp1 + 20*d,
1140 module LidAdhocMultiprintFrame(phase){
1141 if (led_window_style >= 3) {
1142 AdhocMultiprintFrame(phase, lpp13[1], -1);
1146 module LidAroundEdges(){
1147 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1151 module Lid(){ ////toplevel
1152 skew_centre = [0, lpp11[0], lpp11[1]];
1159 translate(skew_centre)
1160 multmatrix([[ 1, 0, 0, 0 ],
1161 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1164 translate(-skew_centre)
1166 LidEdgeFoldClearanceProfile();
1173 translate([0,0,-10])
1174 linear_extrude(height= 20)
1175 ButtonPlan($button_l, 1,0);
1177 translate([0,0,-100])
1178 linear_extrude(height= 200)
1179 ButtonCoverProfile();
1184 HingePortion(hex20, hex21) {
1190 CatchPortion(0, lpp12[1])
1191 CatchCatchProfile();
1193 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1195 // screw holes in the hinge arms
1199 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1202 linextr(-prop_recess_hw, +prop_recess_hw)
1204 for (pa = prop_angles)
1205 PropProfile(pa, 1,1);
1207 // notification led aperture
1208 if (led_window_style)
1209 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1210 translate([0,0,-10])
1211 cylinder(r=nla_r0, h=20);
1212 if (led_window_style >= 2)
1213 translate([0,0, -nla_t])
1214 cylinder(r=nla_r2, height=20);
1219 LidAdhocMultiprintFrame(1);
1222 module HingeLever(){ ////toplevel
1224 // outer body, positive
1225 HingePortion(hex22, hex22 + phone_width/2)
1226 HingeLeverOuterProfile();
1228 // space for the screws
1229 HingePortion(hex26, hex24)
1230 HingeLeverInnerProfile();
1232 // recesses for the nuts
1233 HingePortion(hex23, hex26+1)
1234 HingeLeverNutProfile();
1236 // bores for the screws
1239 // space for the charging cable
1241 Flip_hinge() MicroUSB();
1245 module LidWindow(){ ////toplevel
1246 translate([led_pos[0], -led_pos[1], lpp13[1]])
1248 cylinder(r= nla_r1, h=nla_t);
1249 LidAdhocMultiprintFrame(0);
1252 module LidWindowPrint(){ ////toplevel
1257 module DemoLidWindowSelect(){
1258 translate([led_pos[0], led_pos[1], -100]) {
1259 translate([0, -30, 0]) cube([400, 400, 200]);
1263 module DemoLidWindow(){ ////toplevel
1266 translate([0,40,0]){
1267 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1268 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1272 module HingeLeverPrint(){ ////toplevel
1274 translate([-phone_width/2, phone_height, 0])
1278 module TestSelectLength(){
1279 translate([-30, -200, -20])
1280 cube([30 + 15, 250, 40]);
1283 module TestLength(){ ////toplevel
1290 module TestLengthRight(){ ////toplevel
1298 module TestSelectWidth(){
1299 translate([-30, -(phone_height - 25), -20])
1301 cube([200, 50, 40]);
1304 module TestWidth(){ ////toplevel
1311 module TestLidWidthPrint(){ ////toplevel
1312 rotate([0,180.0]) intersection(){
1318 module TestSelectRearAperture(){
1321 translate([20, 0,0])
1322 cube([42, 2, 1], center=true);
1326 module TestSelectCamera(){
1328 TestSelectRearAperture()
1329 RearCameraAperture();
1330 cube([0.1, 50, 0.1]);
1334 module TestSelectOrdinaryRearApertures(){
1335 TestSelectRearAperture()
1336 OrdinaryRearApertures();
1339 module TestCamera(){ ////toplevel
1346 module TestLidByCamera(){ ////toplevel
1353 module TestLidByCameraPrint(){ ////toplevel
1354 rotate([180,0,0]) TestLidByCamera();
1357 module DemoByCamera(){ ////toplevel
1358 color("blue") TestLidByCamera();
1359 color("red") TestCamera();
1362 module OneKeeper(){ ////toplevel
1363 translate([0, -phone_cnr_rad, 0])
1365 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1369 module OneKeeperPrint(){ ////toplevel
1374 module LidPrint(){ ////toplevel
1379 module TestSelectFrame(){
1380 include = [1,-1] * (epp2i[0] + 4);
1383 cube(1000, center=true);
1384 translate([0,0, -100])
1385 linear_extrude(height=200)
1386 rectfromto(include, inside_br - include);
1390 module TestSelectLidFrame(){
1392 translate([led_pos[0], -led_pos[1], -50])
1393 cylinder(r= nla_r2+3, h=100);
1396 module TestFrameCase(){ ////toplevel
1402 TestSelectOrdinaryRearApertures();
1407 module TestSelectTopApertures(){
1408 translate([-100, -35, -100])
1409 cube([400, 100, 200]);
1410 LidAdhocMultiprintFrame(0);
1411 LidAdhocMultiprintFrame(1);
1414 module TestTopApertures(){ ////toplevel
1418 TestSelectTopApertures();
1422 module TestLidTopAperturesPrint(){ ////toplevel
1423 rotate([0,180,0]) intersection(){
1425 TestSelectLidFrame();
1426 TestSelectTopApertures();
1430 module TestLidWindowTopAperturesPrint(){ ////toplevel
1431 rotate([0,180,0]) intersection(){
1433 TestSelectTopApertures();
1437 module TestFrameLidPrint(){ ////toplevel
1438 rotate([0,180,0]) intersection(){
1440 TestSelectLidFrame();
1444 module ButtonPlanForDemo(z, deep, cut){
1446 ButtonPlan(8, deep, cut);
1449 module HingeScrews(){
1450 Flip_rhs() Flip_bot(1){
1451 for (c= [ hppT, hppB ])
1456 translate([0,0,-.2])
1457 cylinder( r= hingescrew_shaft_dia/2,
1458 h = hingescrew_shaft_len+0.2 );
1460 translate([0,0,+.1])
1461 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1466 module DemoPropAngleSelect(c){
1467 color(c) difference(){
1468 union(){ children(); }
1469 translate([ prop_x_pos, -400, -200 ])
1470 cube([ 400,800,400 ]);
1474 module DemoPropAngle(ang){
1475 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1476 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1484 DemoPropAngleSelect("red") Case();
1487 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1488 PropProfileAssignments(ang) {
1490 rotate([-$prp_theta, 0, 0])
1491 translate([0, $prpp1[0], -$prpp1[1]])
1497 translate([0,0, -hp_k*2])
1498 DemoPropAngleSelect("blue")
1502 module DemoPropAngles(){ ////toplevel
1503 for (i=[0 : len(prop_angles)-1])
1504 translate(i * [0, -100, 100])
1505 DemoPropAngle(prop_angles[i]);
1508 module DemoHingeAngle(ang1,ang2){
1509 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1510 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1521 color("blue") intersection(){
1524 translate([bppJ[0], -400, -200])
1526 cube([400, 800, 400]);
1527 translate([10, -400, -200])
1528 cube([10, 800, 400]);
1533 module DemoHingeAngles(){ ////toplevel
1534 angles = [ 0, 4, 8, 12 ];
1535 echo("angles",angles);
1536 for (i=[0 : len(angles)-1]) {
1537 translate(i * [0, 0, 30]) {
1538 DemoHingeAngle(0,angles[i]);
1539 translate([0, 200, 0])
1540 DemoHingeAngle(angles[i],0);
1545 module DemoSelectAdhocLeftRight(right=0) {
1546 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1547 mirror([1-right, 0,0])
1548 cube([400, 800, 200]);
1551 module DemoLeft(){ ////toplevel
1552 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1553 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1556 module DemoFrame(){ ////toplevel
1557 color("red") TestFrameCase();
1558 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1559 color("black") HingeScrews();
1563 module DemoLanyardEntry(){ ////toplevel
1567 module DemoHingedFrame(){ ///toplevel
1568 color("red") TestFrameCase();
1569 translate([0,0, -2*hp_k])
1570 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1573 color("orange") HingeLever();
1574 color("black") HingeScrews();
1578 module DemoHinge(){ ////toplevel
1579 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1581 translate([0,0, -hp_k*3])
1586 module DemoProfiles(){ ////toplevel
1590 translate([0,0,-1]) color("black") KeeperProfile(1);
1591 color("purple") translate(epp2i)
1592 rotate(atan2vector(epp2i - epp1)) {
1593 translate(lanyard_half_dia * 0.5 * [-3,-1])
1594 LanyardLanyardProfile();
1595 translate(lanyard_half_dia * 0.5 * [-3,+1])
1596 translate([0,-1] * case_th_side)
1597 LanyardLanyardProfile(true);
1601 LanyardMainChannelProfile();
1602 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1603 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1610 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1612 color("blue") ButtonCoverProfile();
1614 rectfromto(bppQ, demopoint_QR);
1615 rectfromto(bppR, demopoint_QR);
1619 translate([-20,0]) {
1620 color("black") ButtonPlanForDemo(-2, 0,1);
1621 color("red" ) ButtonPlanForDemo(-4, 1,1);
1622 color("blue") ButtonPlanForDemo(-6, 1,0);
1625 translate([0, -30]) {
1628 color("blue") HingeLidProfile();
1629 color("red") HingeBaseProfile();
1630 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1634 translate([-30, -60 + 30*f]) {
1635 translate([0,0,-4]) EdgeProfile();
1636 %translate([0,0,-10]) HingeBaseProfile();
1637 translate([0,-2] * f * hp_k) {
1638 translate([0,0,-4]) LidEdgeProfile();
1639 %translate([0,0,-10]) %HingeLidProfile();
1641 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1642 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1643 translate([0,0,0]) color("red") difference(){
1644 HingeLeverOuterProfile();
1645 HingeLeverInnerProfile();
1647 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1652 translate([20,-30]) {
1655 //translate([0,0,1]) CatchCutProfile();
1656 color("blue") CatchCatchProfile();
1657 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
1660 translate([40,-30]) {
1664 PropProfile(10, 1, 0);
1669 translate([60,-30]) {
1670 PropAggregateProfile();