5 phone = [ 75.0, 145.0 ];
9 prop_angles = [ 15, 30, 45, 60 ];
11 bumper = [ 0.250, -0.025 ];
12 // ^ One side. Overall size is increased by twice this.
13 // If no bumpers, is the gap around the phone.
19 button_cutout_depth = 9;
21 phone_edge_thick = 9.0;
22 phone_total_thick = 12.0;
23 phone_backside_slope_inner = 1.5; // larger means shallower
24 phone_backside_slope_outer = 1.0; // larger means shallower
26 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
27 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
29 jack_pos = [ 14.38, 7.96 ];
30 jack_dia = 10.64 + .5; // some jack I had lying around
32 noisecancelmic_pos = [ 19.54, 7.37 ]; // from rhs
33 noisecancelmic_dia = 4.00;
35 //fingerpushhole_dias = [ 15, 18 ];
36 fingerpushhole_dias = [];
38 rearspeaker_pos_bl = [ 12.64, 18.72 ];
39 rearspeaker_size = [ 3.76, 7.36 ];
41 microusb_above = 3.27 - 0.25;
43 microusb_width = 16.12 + 1.25;
50 case_struts_count = 6;
51 case_struts_solid_below = 1.00;
52 case_struts_solid_above = 0.75;
53 case_struts_width = 0.10;
57 keeper_inner_width = 2.75;
58 keeper_inner_height = 2.75;
59 keeper_slant_slope = 2; // larger means steeper
61 keeper_gap_z_top = 0.25;
62 keeper_gap_z_bot = 0.75;
64 keeper_gap_x_holes = 0.75;
66 keeper_side = 0; // 0 = lhs; 1 = rhs
77 foldover_lever_gap = 0.50;
79 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
80 hingescrew_shaft_len = 12;
81 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
82 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
83 hingescrew_head_th = 1.38 + 0.75;
84 hingescrew_head_dia = 3.92;
85 lever_cover_th = 0.75;
92 buttonishleg_default_l_is_fudge = 10;
94 hinge_base_slope = 1.5; // bigger is steeper
96 strut_min_at_end = 1.5;
99 hinge_x_postscrew_gap = 0.75;
100 hinge_x_arms_gap = 0.35;
101 hinge_r_arms_gap = 0.55;
103 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
107 catch_thickness = 1.0;
108 catch_side_gap = 0.75; // each side
112 catch_finger_height = 1.5;
113 catch_finger_depth = 2.5;
115 prop_recess_under = 0.50;
116 prop_recess_slop = 0.200; // each side
121 prop_side_gap = 0.75; // each side
122 prop_caserecess_behind = 0.75;
123 prop_caserecess_taper = 0.25; // each side
125 // ---------- calculated ----------
127 phone_width = (phone + bumper*2)[0];
128 phone_height = (phone + bumper*2)[1];
130 inside_br = [phone_width, -phone_height];
132 //echo(camera_pos_tl + bumper,
133 // camera_pos_br + bumper);
135 // ----- could be changed -----
136 lid_buttoncover_gap = lid_gap_x;
137 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
139 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
141 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
143 //prop_nose_len = case_th_lid - prop_recess_under;
144 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
145 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
148 //lid_lip_overlap_width xxx bad name = ;
149 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
152 epp1 = [0, -phone_edge_thick];
153 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
154 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
155 epp3 = epp2i + [10, 0];
156 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
157 epp4 = epp5 + [-1,0] * case_th_side;
160 kppd = kppe + [1,0] * keeper_inner_width;
161 kppc = kppd + [0,1] * keeper_th_z;
162 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
163 kppf = kppe - [0,1] * keeper_inner_height;
164 kppa = [ kppb[0], kppf[1] ];
166 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
167 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
169 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
171 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
172 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
174 case_bottom_z = epp2o[1] - case_th_bottom;
178 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
179 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
180 bppS = [ epp1[0], bppR[1] ];
181 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
182 bppP = bppQ + [0,1] * lid_buttoncover_gap;
183 bppO = [ bppN[0], bppP[1] ];
184 bppL = lpp10 + [5,0];
185 bppK = [ bppL[0], bppN[1] ];
186 bppJ = [ bppN[0], bppL[1] ];
189 hp_rn = hingescrew_nut_dia/2;
190 hp_r2_min = hp_rn + lever_cover_th;
191 hp_rs = hingescrew_shaft_dia/2;
192 hp_r1_min = hp_rs + hingemount_th;
194 hp_r1 = max(hp_r1_min, hp_r2_min);
198 hppS = epp2o + [0,-1] * case_th_bottom;
199 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
201 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
202 0.5 * (hppU + hppS)[1] ];
203 hppT = [ hppM[0], hppU[1] - hp_r1 ];
204 hppB = hppT + [0,-1] * hp_k;
206 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
207 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
208 hppE = [ hppE_x, hppE_y ];
210 // hinge elevation x coords
212 hingescrew_portion_len =
213 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
215 hex20 = max(epp2o[0],
217 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
218 hex21 = hex20 + hingescrew_portion_len;
219 hex22 = hex21 + hinge_x_gap;
220 hex23 = hex22 + hingescrew_portion_len
221 - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
222 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
223 //echo(hex20, hex21, hex22, hex23, hex24);
224 //echo(hingescrew_portion_len);
228 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
229 cppA = cppJ + [lid_gap_x, -lid_gap_z];
230 cppB = [ epp0[0], cppA[1] ];
231 cppP = [ epp4[0], cppJ[1] ];
233 cppS = cppJ + [0,-1] * catch_len;
234 cppD = [ cppA[0], cppS[1] + catch_slop ];
235 cppC = [ cppB[0], cppD[1] ];
236 cppT = cppS + [1,0] * catch_depth;
237 cppU = cppT + [0,-1] * catch_height;
238 cppV = [ cppS[0], cppU[1] - catch_depth ];
240 cppR = 0.5*(cppP + cppJ);
242 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
244 cppV[1] - (catch_finger_height - cp_rQ) ];
245 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
249 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
251 prcp2 = [ epp4[0], case_bottom_z ];
253 prop_caserecess_buildout_r = prcp2[0] - epp2o[0];
255 prc_r1 = prop_end_dia/2;
256 prc_r3 = prc_r1 + prop_recess_slop;
259 prcp1 = [ prcp2[0] + prop_caserecess_behind + prc_r3,
262 // ---------- modules ----------
264 module KeeperProfile(slant=0){
265 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
266 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
269 module EdgeProfile(){
272 translate(epp3) square(case_th_bottom*2, center=true);
273 circleat(epp2o, r=case_th_bottom);
274 circleat(epp1, r=case_th_side);
275 rectfromto(epp0, epp4);
277 polygon([ epp5 + [0,10],
284 module LidEdgeProfile(){
293 circleat(lpp12, r=lp_r12);
294 rectfromto( lpp12 + [-10, 0],
295 lpp12 + [+10, +10] );
299 module ButtonCoverProfile(){
301 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
309 module ButtonPlan(l, deep, cut){
311 (cut ? 0 : lid_buttoncover_gap);
314 (deep ? lid_buttoncover_overlap : 0);
316 C = [0,0]; // by definition
320 B0 = C + [0,-1] * button_cutout_depth;
321 B1 = B0 + [0,1] * epsilon;
323 r0 = 0.5 * (T[1] - B0[1]);
324 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
325 H = A + [0,-1] * delta;
331 E1 = E0 + [1,0] * epsilon;
333 I0 = [ E0[0], H[1] ];
334 I1 = [ E1[0], H[1] ];
337 for (m=[0,1]) mirror([m,0])
338 circleat(H, r0 - epsilon);
340 for (m=[0,1]) mirror([m,0]) {
350 circleat(D, r0 + epsilon);
355 module CatchCatchProfile(){
357 for (c=[ cppR, cppQ ])
361 circleat(lpp12, lp_r12);
362 circleat(lpp12 + [5,0], lp_r12);
363 rectfromto(cppP, cppP + [5,0.1]);
365 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
368 module CatchCutProfile(){
380 module Flip_rhs(yn=[0,1]) {
382 translate([phone_width/2, 0, 0])
383 mirror([$rhsflip,0,0])
384 translate([-phone_width/2, 0, 0])
389 module Flip_bot(yn=[0,1]) {
391 translate([0, -phone_height/2, 0])
392 mirror([0, $botflip, 0])
393 translate([0, phone_height/2, 0])
398 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
401 translate([0, -phone_cnr_rad, 0])
403 linear_extrude(height = phone_height - phone_cnr_rad*2)
407 Flip_rhs() Flip_bot() {
408 translate([+1,-1] * phone_cnr_rad)
413 translate([-1,0] * phone_cnr_rad)
415 rectfromto([0,-20],[10,20]);
417 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
423 translate([ phone_width - phone_cnr_rad, 0,0 ])
425 linear_extrude(height = phone_width - phone_cnr_rad*2)
429 translate([0,0, fill_zstart])
430 mirror([0,0, fill_downwards])
431 linear_extrude(height = fill_th)
432 rectfromto([+1,-1] * phone_cnr_rad,
433 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
436 module CaseAperture(pos, dia, $fn) {
438 translate([ pos[0] + bumper[0],
441 rotate([-90, theta, 0])
442 cylinder(r = dia/2 / cos(theta),
446 module SideButton(y, y_ref_sign, l){
448 // +1 measured from top of actual phone to top of button
449 // -1 measured from bottom of actual phone to bottom of button
450 // 0 y is centre of button in coordinate system
452 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
453 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
456 translate([0, eff_y, 0])
460 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
461 $button_leg_only = true;
462 SideButton(y, y_ref_sign, l) children();
466 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
467 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
468 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
469 Flip_rhs( ) LidButtonishLeg(14, -1) children();
470 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
473 module Struts(x_start, z_min, th){
474 // if th is negative, starts at z_min and works towards -ve z
475 // and object should then be printed other way up
476 for (i= [1 : 1 : case_struts_count]) {
480 mirror([0,0, th<0 ? 1 : 0])
482 -phone_height * i / (case_struts_count+1),
483 case_struts_solid_below])
484 linear_extrude(height= abs(th)
485 -(case_struts_solid_below+case_struts_solid_above))
486 rectfromto([ x_start, -0.5 * case_struts_width ],
487 [ phone_width - x_start, +0.5 * case_struts_width ]);
491 module OrdinaryRearAperture(rhs,bot, pos){
492 Flip_rhs(rhs) Flip_bot(bot)
495 translate(pos + bumper)
503 linextr(-epp2i[0], 60)
504 translate([0.5 * phone_width, 0, 0])
505 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
506 [+microusb_width/2, epp0[1] + -microusb_above]);
510 module OrdinaryRearApertures(){
512 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
513 rectfromto(-rearspeaker_gap,
514 rearspeaker_size + rearspeaker_gap);
516 // finger hole to remove phone
517 if (len(fingerpushhole_dias))
518 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
520 scale(fingerpushhole_dias)
524 module RearCameraAperture(){
527 linear_extrude(height = 20)
530 rectfromto(camera_pos_tl, camera_pos_br);
533 module HingeLidProfile(){
535 circleat(hppT, hp_r1);
536 circleat(lpp12, lp_r12);
544 module HingeBaseProfile(){
547 circleat(hppB, hp_r1);
548 circleat(hppE, hp_r1);
549 circleat(epp2o, case_th_bottom);
550 circleat(hppB + [10,0], hp_r1);
552 polygon([epp5, epp1, epp2i, epp3, bppL]);
556 module HingeLeverOuterProfile(){
558 circleat(hppT, hp_r2);
559 circleat(hppB, hp_r2);
563 module HingeLeverInnerProfile(){
564 for (c = [hppT, hppB]) {
567 for (y=[0, c[1] - hppM[1]])
574 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
575 translate(hinge_origin)
577 translate(-hinge_origin)
581 module HingePortion(x0,x1){
582 Flip_rhs() Flip_bot(1)
586 linear_extrude(height=x1-x0)
590 module CatchPortion(width){
591 translate([phone_width/2, 0,0])
593 linextr(-width/2, width/2)
598 AroundEdges(epp3[1], case_th_bottom, 1)
602 module Case(){ ////toplevel
607 // ledge (fixed keeper)
608 Flip_rhs(1-keeper_side) intersection(){
610 linear_extrude(height = phone_height + phone_cnr_rad * 2)
613 // outline of the whole case, to stop it protruding
614 translate([0,0, -25])
615 linear_extrude(height = 50)
618 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
622 HingePortion(hex20, hex21) HingeBaseProfile();
624 // buildout for prop recess
626 linextr(case_bottom_z, epp2i[1])
629 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
631 r = epp2o[0] - prcp2[0]);
636 Flip_rhs(keeper_side)
637 translate([0, -phone_cnr_rad, 0])
639 linear_extrude(height = phone_height + phone_cnr_rad * 2)
642 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
643 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
647 RearCameraAperture();
649 // struts (invisible, because they're buried in the case)
650 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
655 if (!($button_leg_only && enable_support))
658 linear_extrude(height= 20)
659 ButtonPlan($button_l, 0,1);
660 if ($button_leg_only)
662 translate([phone_width/2, -400, kppe[1]])
663 mirror([1-abs($rhsflip - keeper_side),0,0])
664 cube([400, 800, 50]);
667 translate([-400, -400, kppd[1]])
671 translate([0,0, -bppR[0]])
672 linear_extrude(height= 20)
673 ButtonPlan($button_l, 1,1);
678 // apertures along top edge
679 CaseAperture(jack_pos, jack_dia, 8);
681 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
683 OrdinaryRearApertures();
687 // gaps for the lid's hinge arms
688 HingePortion(hex20 - hinge_x_arms_gap,
689 hex21 + hinge_x_arms_gap)
692 circle(r= hinge_r_arms_gap, $fn= 8);
695 // screw holes in the hinge arms
699 CatchPortion(catch_width + catch_side_gap*2)
706 linextr(-prop_recess_hw, +prop_recess_hw)
709 circleat(prcp2 + 20*(abs(zs) * [0,-1] +
710 zs * [1,0] * prop_caserecess_taper),
716 module Lid(){ ////toplevel
719 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
727 linear_extrude(height= 20)
728 ButtonPlan($button_l, 1,0);
730 translate([0,0,-100])
731 linear_extrude(height= 200)
732 ButtonCoverProfile();
737 HingePortion(hex20, hex21) HingeLidProfile();
740 CatchPortion(catch_width)
743 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
745 // screw holes in the hinge arms
750 module HingeLever(){ ////toplevel
752 // outer body, positive
753 HingePortion(hex22, hex22 + phone_width/2)
754 HingeLeverOuterProfile();
756 // space for the screws
757 HingePortion(hex23, hex24)
758 HingeLeverInnerProfile();
760 // bores for the screws
763 // space for the charging cable
765 Flip_hinge() MicroUSB();
769 module HingeLeverPrint(){ ////toplevel
774 module TestSelectLength(){
775 translate([-30, -200, -20])
776 cube([30 + 15, 250, 40]);
779 module TestLength(){ ////toplevel
786 module TestLengthRight(){ ////toplevel
794 module TestSelectWidth(){
795 translate([-30, -(phone_height - 25), -20])
800 module TestWidth(){ ////toplevel
807 module TestLidWidthPrint(){ ////toplevel
808 rotate([0,180.0]) intersection(){
814 module TestSelectRearAperture(){
818 cube([42, 2, 1], center=true);
822 module TestSelectCamera(){
824 TestSelectRearAperture()
825 RearCameraAperture();
826 cube([0.1, 50, 0.1]);
830 module TestSelectOrdinaryRearApertures(){
831 TestSelectRearAperture()
832 OrdinaryRearApertures();
835 module TestCamera(){ ////toplevel
842 module TestLidByCamera(){ ////toplevel
849 module TestLidByCameraPrint(){ ////toplevel
850 rotate([180,0,0]) TestLidByCamera();
853 module DemoByCamera(){ ////toplevel
854 color("blue") TestLidByCamera();
855 color("red") TestCamera();
858 module OneKeeper(){ ////toplevel
859 translate([0, -phone_cnr_rad, 0])
861 linear_extrude(height = phone_height - phone_cnr_rad * 2)
865 module OneKeeperPrint(){ ////toplevel
870 module LidPrint(){ ////toplevel
875 module TestSelectPropRecesses(posns){
877 translate([phone_width/2, -phone_height]){
878 square([ 3, 500 ], center=true);
881 for (dy=[ -prp5[0], -prp2[0] ])
883 square([prop_main_width+5, 5], center=true);
888 module TestSelectFrame(){
889 include = [1,-1] * (epp2i[0] + 4);
892 cube(1000, center=true);
893 translate([0,0, -100])
894 linear_extrude(height=200)
895 rectfromto(include, inside_br - include);
899 module TestSelectLidFrame(){
901 TestSelectPropRecesses(prop_lid_posns);
904 module TestFrameCase(){ ////toplevel
910 TestSelectOrdinaryRearApertures();
915 module TestFrameLidPrint(){ ////toplevel
916 rotate([0,180,0]) intersection(){
918 TestSelectLidFrame();
922 module ButtonPlanForDemo(z, deep, cut){
924 ButtonPlan(8, deep, cut);
927 module HingeScrews(){
928 Flip_rhs() Flip_bot(1){
929 for (c= [ hppT, hppB ])
935 cylinder( r= hingescrew_shaft_dia/2,
936 h = hingescrew_shaft_len+0.2 );
939 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
944 module DemoFrame(){ ////toplevel
945 color("red") TestFrameCase();
946 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
947 color("black") HingeScrews();
951 module DemoHingedFrame(){ ///toplevel
952 color("red") TestFrameCase();
953 translate([0,0, -2*hp_k])
954 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
957 color("orange") HingeLever();
958 color("black") HingeScrews();
962 module DemoHinge(){ ////toplevel
964 translate([0,0, -hp_k*3])
968 module DemoProfiles(){ ////toplevel
972 translate([0,0,-1]) color("black") KeeperProfile(1);
978 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
980 color("blue") ButtonCoverProfile();
982 rectfromto(bppQ, demopoint_QR);
983 rectfromto(bppR, demopoint_QR);
988 color("black") ButtonPlanForDemo(-2, 0,1);
989 color("red" ) ButtonPlanForDemo(-4, 1,1);
990 color("blue") ButtonPlanForDemo(-6, 1,0);
993 translate([0, -30]) {
996 color("blue") HingeLidProfile();
997 color("red") HingeBaseProfile();
998 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
999 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
1002 translate([20,-30]) {
1005 //translate([0,0,1]) CatchCutProfile();
1006 color("blue") CatchCatchProfile();
1007 color("red") difference(){ EdgeProfile(); CatchCutProfile(); }