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;
172 lanyard_entry_rel_breadth = 2;
173 lanyard_channel_len = 15;
174 rearspeaker_pos_bl = [ 12.64, 18.72 ];
175 rearspeaker_size = [ 3.76, 7.36 ];
177 microusb_above = 3.27 - 0.25;
178 microusb_below = 0.0;
179 microusb_width = 16.12 + 1.25;
181 case_th_bottom = 2.5;
186 lid_screen_gap_extra = .66;
188 case_struts_count = 6;
189 case_struts_solid_below = 1.00;
190 case_struts_solid_above = 0.75;
191 case_struts_width = 0.10;
195 keeper_inner_width = 2.75;
196 keeper_inner_height = 2.75;
197 keeper_slant_slope = 2; // larger means steeper
199 keeper_gap_z_top = 0.25;
200 keeper_gap_z_bot = 0.75;
202 keeper_gap_x_holes = 0.75;
204 keeper_side = 0; // 0 = lhs; 1 = rhs
211 lid_edgepart_width = 5.0;
212 lid_buttoncover_thick = 1.3;
213 lid_buttoncover_reinf = 1.0;
218 foldover_lever_gap = 0.50;
220 // properties of the hinge fasteners
221 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
222 hingescrew_shaft_len = 12;
223 hingescrew_fasteners_extra_thick = 0.40;
224 // ^ amount of thread protruding if everything was completely nominal
225 // and we are using two nuts
226 hingescrew_nut_access_dia = 4.72 + 0.50;
227 // ^ washer is 4.72 dia
228 // also, want to get pliers or tiny spanner in to do up locknut
229 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
230 hingescrew_nut_thick = 1.93;
231 hingescrew_head_th = 1.38 + 0.75;
232 hingescrew_head_dia = 3.92;
234 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
236 lever_cover_th = 0.75;
238 hingemount_wd = 4.8725;
243 button_l_fudge = 4.4;
244 buttonishleg_default_l_is_fudge = 10;
246 hinge_base_slope = 1.5; // bigger is steeper
248 strut_min_at_end = 1.5;
251 hinge_x_postscrew_gap = 0.75;
252 hinge_x_arms_gap = 0.35;
253 hinge_r_arms_gap = 0.55;
255 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
259 catch_thickness = 1.3;
260 catch_side_gap = 0.75; // each side
264 catch_finger_height = 1.5;
265 catch_finger_depth = 2.5;
266 catch_catch_slope = 0.25;
268 catch_topcurve_r = 5.0;
270 prop_recess_under = 0.50;
271 prop_recess_slop = 0.200; // each side
276 prop_side_gap = 0.75; // each side
277 prop_lidrecess_behind = 0.75;
278 prop_caserecess_behind = 0.75;
279 prop_caserecess_taper = 0.45; // one side only
281 prop_prong_heel_slope = 0.5;
283 lid_fold_clearance_antislop = 0.5;
285 // ---------- calculated ----------
287 phone_width = (phone + bumper*2)[0];
288 phone_height = (phone + bumper*2)[1];
290 inside_br = [phone_width, -phone_height];
292 prop_prong_h = prop_main_th;
294 //echo(camera_pos_tl + bumper,
295 // camera_pos_br + bumper);
297 // ----- could be changed -----
298 lid_buttoncover_gap = lid_gap_x;
299 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
301 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
303 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
305 //prop_nose_len = case_th_lid - prop_recess_under;
306 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
307 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
310 //lid_lip_overlap_width xxx bad name = ;
311 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
314 epp1 = [0, -phone_edge_thick];
315 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
316 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
317 epp3 = epp2i + [10, 0];
318 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
319 epp4 = epp5 + [-1,0] * case_th_side;
322 kppd = kppe + [1,0] * keeper_inner_width;
323 kppc = kppd + [0,1] * keeper_th_z;
324 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
325 kppf = kppe - [0,1] * keeper_inner_height;
326 kppa = [ kppb[0], kppf[1] ];
328 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
329 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
331 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
332 // exact x posn not very important; must extend past end of keeper
335 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
336 + lid_screen_gap_extra ];
337 // ^ beam theory says to maximise force before contact,
338 // the gap below the `beam' (the lid) must be 1/3
339 // the thickness (ie the lid thickness) if the beam
340 // is solid, or 1/2 if it has a top and bottom only.
341 // ours is mostly solid.
343 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
346 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
347 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
349 case_bottom_z = epp2o[1] - case_th_bottom;
353 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
354 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
355 bppS = [ epp1[0], bppR[1] ];
356 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
357 bppP = bppQ + [0,1] * lid_buttoncover_gap;
358 bppO = [ bppN[0], bppP[1] ];
359 bppL = lpp10 + [5,0];
360 bppK = [ bppL[0], bppN[1] ];
361 bppJ = [ bppN[0], bppL[1] ];
362 bppU = [ bppJ[0], lpp12[1] ];
366 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
368 // notification led aperture
370 nla_r0 = led_aperture/2;
371 nla_r1 = nla_r0 + led_window_ledge;
372 nla_r2 = nla_r1 + multicolour_gap;
374 led_window_style >= 3 ? initial_layer_thick :
375 led_window_style >= 2 ? led_window_ledge : 0;
379 hp_rn = hingescrew_nut_access_dia/2;
380 hp_r2_min = hp_rn + lever_cover_th;
381 hp_rs = hingescrew_shaft_dia/2;
382 hp_r1_min = hp_rs + hingemount_th;
384 hp_r1 = max(hp_r1_min, hp_r2_min);
388 hppS = epp2o + [0,-1] * case_th_bottom;
389 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
391 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
392 0.5 * (hppU + hppS)[1] ];
393 hppT = [ hppM[0], hppU[1] - hp_r1 ];
394 hppB = hppT + [0,-1] * hp_k;
396 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
397 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
398 hppE = [ hppE_x, hppE_y ];
400 // hinge elevation x coords
402 hex20 = max(epp2o[0],
404 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
405 hex21 = hex20 + hingemount_wd;
406 hex22 = hex21 + hinge_x_gap;
407 hex27 = hex20 + hingescrew_shaft_len;
408 hex24 = hex27 + hinge_x_postscrew_gap;
409 hex23 = hex27 - (hingescrew_nut_thick*2
410 + hingescrew_fasteners_extra_thick);
411 hex26 = hex23 + hingescrew_nut_thick * 2/3;
413 echo(hex20, hex21, hex22, hex23, hex24);
414 // 6, 10.8725, 10.9975, 13.74, 18.75
415 module chk(act,exp) {
416 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
417 else echo("ok", act);
425 lid_fold_clearance_skew =
426 (lpp10[1] - hppB[1]) /
427 (lpp10[0] - hppB[0]);
429 echo("SK",lid_fold_clearance_skew);
433 cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
434 cppA = cppJ + [lid_gap_x, -lid_gap_z];
435 cppB = [ epp0[0], cppA[1] ];
436 cppP = [ epp4[0], cppJ[1] ];
438 cppS = cppJ + [0,-1] * catch_len;
439 cppD = [ cppA[0], cppS[1] + catch_slop ];
440 cppC = [ cppB[0], cppD[1] ];
441 cppT = cppS + [1, -catch_catch_slope] * catch_depth;
442 cppU = cppT + [0,-1] * catch_height;
443 cppV = [ cppS[0], cppU[1] - catch_depth ];
445 cppR = 0.5*(cppP + cppJ);
447 cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
449 cppV[1] - (catch_finger_height - cp_rQ) ];
450 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
454 ly_r = lanyard_half_dia / 2;
457 ly_theta = -atan2vector(epp2i - epp1);
458 ly_o = epp2i + 3 * ly_r * unitvector2d(epp1 - epp2i);
460 max_case_bottom_edge_thickness =
462 + sin(ly_theta) * (epp2i-epp2o)[0];
464 ly_q_z = -(ly_rc + ly_r);
465 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
467 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
469 // prop recess in case
471 prop_x_pos = phone_width/2;
473 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
475 prc_r1 = prop_end_dia/2;
476 prc_r3 = prc_r1 + prop_recess_slop;
478 prcp2 = [ epp4[0] + prop_buildout_less,
481 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
483 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
484 epp2i[1] - prc_r3 - prop_recess_under];
486 // prop recess in lid
488 prl_r10 = prop_end_dia/2;
489 prl_r10o = prl_r10 + prop_recess_slop;
491 prlp10 = lpp10 + [1,1] * prl_r10o
492 + [1,0] * prop_lidrecess_behind
493 + [0,1] * prop_recess_under;
498 $prpp11 = [0, prop_taper_len];
502 // ---------- modules ----------
504 module AdhocMultiprintFrame(phase, z0, zs) {
505 // from z0 to z0 + zs*layer
506 extra = phase * (initial_layer_width + multicolour_gap) + 5;
507 xextra = extra + -epp4[0];
508 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
509 yextra = extra + -epp4[0];
510 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
511 p0 = [ xrange[0], yrange[0] ];
512 p1 = [ xrange[1], yrange[1] ];
515 mirror([0,0, zs<0 ? 1 : 0])
516 linear_extrude(height= initial_layer_thick)
518 rectfromto(p0 - [1,1] * initial_layer_width,
519 p1 + [1,1] * initial_layer_width);
524 module KeeperProfile(slant=0){
525 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
526 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
529 module EdgeProfile(){
532 translate(epp3) square(case_th_bottom*2, center=true);
533 circleat(epp2o, r=case_th_bottom);
534 circleat(epp1, r=case_th_side);
535 rectfromto(epp0, epp4);
537 polygon([ epp5 + [0,10],
544 module LanyardLanyardProfile(entry=false){
546 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
547 translate(xs * 0.5 * lanyard_half_dia * [1,0])
548 circle(r= lanyard_half_dia/2);
552 module LanyardCurveChannelProfile(){
553 translate([0, -ly_r])
554 LanyardLanyardProfile();
557 module LanyardEntryChannelProfile(){
558 LanyardLanyardProfile(true);
561 module LanyardMainChannelProfile(){
562 LanyardCurveChannelProfile();
564 square(center=true, ly_r * [6, 2]);
566 translate(ly_r * [3 * xs, -1])
571 module LanyardEntryOuterProfile(){
572 circleat([ly_re + ly_r, 0], ly_re);
575 module LanyardEntry(){
581 translate([d_x, 0, q_z]) {
584 rotate_extrude(convexity=10)
587 LanyardCurveChannelProfile();
595 linear_extrude(height=20)
597 LanyardEntryChannelProfile();
599 translate([0, ly_r*2, 0])
601 linear_extrude(height = ly_r*4){
603 rectfromto([d_x, q_z], [ly_r, 0]);
604 circleat([d_x, q_z], ly_rc);
608 translate([0,0,q_z]){
611 translate([0, oec_y, 0]){
613 translate(ly_re * [-1,0,-2])
614 cube(ly_re * [2,1,2]);
615 rotate_extrude(convexity=10)
616 LanyardEntryOuterProfile();
621 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
622 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
627 linear_extrude(height=20)
628 LanyardEntryOuterProfile();
633 module LanyardCutout(l){
635 linear_extrude(height=l)
637 LanyardMainChannelProfile();
640 translate(ee * l * [-1,0])
646 module LidEdgeProfile(){
657 circleat(lpp12, r=lp_r12);
658 rectfromto( lpp12 + [-10, 0],
659 lpp12 + [+10, +10] );
663 module LidEdgeFoldClearanceProfile(){
664 translate([-lid_fold_clearance_antislop, 0])
673 module ButtonCoverProfile(){
675 polygon(concat([ bppM, bppP, bppO, bppJ ],
676 (enable_support && !$button_suppress_over_keeper
677 ? [ bppU, bppV, bppW ] : []),
686 module ButtonPlan(l, deep, cut){
688 (cut ? 0 : lid_buttoncover_gap);
691 (deep ? lid_buttoncover_overlap : 0);
693 C = [0,0]; // by definition
697 B0 = C + [0,-1] * button_cutout_depth;
698 B1 = B0 + [0,1] * epsilon;
700 r0 = 0.5 * (T[1] - B0[1]);
701 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
702 H = A + [0,-1] * delta;
708 E1 = E0 + [1,0] * epsilon;
710 I0 = [ E0[0], H[1] ];
711 I1 = [ E1[0], H[1] ];
714 for (m=[0,1]) mirror([m,0])
715 circleat(H, r0 - epsilon);
717 for (m=[0,1]) mirror([m,0]) {
727 circleat(D, r0 + epsilon);
732 module ButtonCoverReinf(){ ////toplevel
735 linear_extrude(height=0.01)
737 ButtonCoverProfile();
738 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
741 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
742 circle(r= lid_buttoncover_reinf);
743 translate([-20,0]) square(40, center=true);
748 module CatchCatchProfile(){
750 for (c=[ cppR, cppQ ])
754 circleat(lpp12, lp_r12);
755 circleat(lpp12 + [5,0], lp_r12);
756 rectfromto(cppP, cppP + [5,0.1]);
758 polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
761 module CatchCutProfile(){
773 module Flip_rhs(yn=[0,1]) {
775 translate([phone_width/2, 0, 0])
776 mirror([$rhsflip,0,0])
777 translate([-phone_width/2, 0, 0])
782 module Flip_bot(yn=[0,1]) {
784 translate([0, -phone_height/2, 0])
785 mirror([0, $botflip, 0])
786 translate([0, phone_height/2, 0])
791 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
794 translate([0, -phone_cnr_rad, 0])
796 linear_extrude(height = phone_height - phone_cnr_rad*2)
800 Flip_rhs() Flip_bot() {
801 translate([+1,-1] * phone_cnr_rad)
806 translate([-1,0] * phone_cnr_rad)
808 rectfromto([0,-20],[10,20]);
810 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
816 translate([ phone_width - phone_cnr_rad, 0,0 ])
818 linear_extrude(height = phone_width - phone_cnr_rad*2)
822 translate([0,0, fill_zstart])
823 mirror([0,0, fill_downwards])
824 linear_extrude(height = fill_th)
825 rectfromto([+1,-1] * phone_cnr_rad,
826 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
829 module CaseAperture(pos, dia, $fn) {
831 translate([ pos[0] + bumper[0],
834 rotate([-90, theta, 0])
835 cylinder(r = dia/2 / cos(theta),
839 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
841 // +1 measured from top of actual phone to top of button
842 // -1 measured from bottom of actual phone to bottom of button
843 // 0 y is centre of button in coordinate system
845 $button_suppress_over_keeper= suppress_over_keeper;
846 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
847 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
850 translate([0, eff_y, 0])
854 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
855 $button_leg_only = true;
856 SideButton(y, y_ref_sign, l) children();
860 Flip_rhs(1) SideButton(15.580, +1, 8.9 ) children(); // power
861 Flip_rhs(1) SideButton(48.700, -1, 8.920 ) children(); // camera
862 Flip_rhs(0) SideButton(30.800, +1, 21.96, 1) children(); // volume
863 Flip_rhs( ) LidButtonishLeg(14, -1) children();
864 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
867 module Struts(x_start, z_min, th){
868 // if th is negative, starts at z_min and works towards -ve z
869 // and object should then be printed other way up
870 for (i= [1 : 1 : case_struts_count]) {
874 mirror([0,0, th<0 ? 1 : 0])
876 -phone_height * i / (case_struts_count+1),
877 case_struts_solid_below])
878 linear_extrude(height= abs(th)
879 -(case_struts_solid_below+case_struts_solid_above))
880 rectfromto([ x_start, -0.5 * case_struts_width ],
881 [ phone_width - x_start, +0.5 * case_struts_width ]);
885 module OrdinaryRearAperture(rhs,bot, pos){
886 Flip_rhs(rhs) Flip_bot(bot)
889 translate(pos + bumper)
897 linextr(-epp2i[0], 60)
898 translate([0.5 * phone_width, 0, 0])
899 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
900 [+microusb_width/2, epp0[1] + -microusb_above]);
904 module OrdinaryRearApertures(){
906 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
907 rectfromto(-rearspeaker_gap,
908 rearspeaker_size + rearspeaker_gap);
910 // finger hole to remove phone
911 if (len(fingerpushhole_dias))
912 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
914 scale(fingerpushhole_dias)
918 module RearCameraAperture(){
921 linear_extrude(height = 20)
924 rectfromto(camera_pos_tl, camera_pos_br);
927 module HingeLidProfile(){
929 circleat(hppT, hp_r1);
930 circleat(lpp12, lp_r12);
938 module HingeBaseProfile(){
941 circleat(hppB, hp_r1);
942 circleat(hppE, hp_r1);
943 circleat(epp2o, case_th_bottom);
944 circleat(hppB + [10,0], hp_r1);
946 polygon([epp5, epp1, epp2i, epp3, bppL]);
950 module HingeLeverOuterProfile(){
952 circleat(hppT, hp_r2);
953 circleat(hppB, hp_r2);
957 module HingeLeverInnerProfile(){
959 c = s > 0 ? hppT : hppB;
962 rotate(s<0 ? -40 : 0)
971 module HingeLeverNutProfile(){
972 for (c= [hppB, hppT]) {
974 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
978 module Flip_hinge(doflip=1){
979 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
980 translate(hinge_origin)
981 rotate([doflip*180,0,0])
982 translate(-hinge_origin)
986 module HingePortion(x0,x1){
987 Flip_rhs() Flip_bot(1)
991 linear_extrude(height=x1-x0)
995 module CatchPortion(xwidth, ztop){
996 width = catch_width + xwidth;
997 w = width + catch_topcurve_r*2 + 1;
998 translate([phone_width/2, 0,0]){
1003 translate([0, 50, 0])
1005 linear_extrude(height=100){
1006 for (m=[0,1]) mirror([m,0,0]) {
1008 translate([w/2, ztop - catch_topcurve_r])
1009 circle(catch_topcurve_r);
1010 translate([w/2, -50])
1011 square(catch_topcurve_r*2, center=true);
1020 AroundEdges(epp3[1], case_th_bottom, 1)
1024 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
1026 module PropProfileAssignments(gamma){
1027 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
1029 p = phone_height + prlp10[0] - hppB[0];
1032 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
1034 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
1035 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
1037 $prp_theta = 90 - $prp_alpha;
1038 beta = 180 - $prp_alpha - gamma;
1041 //echo("abc", a,b,c);
1043 v1 = [ [ cos(psi), -sin(psi) ], // x
1044 [ sin(psi), cos(psi) ] ]; // y
1046 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1049 $prp_r11 = prop_main_th/2;
1051 $prpp1 = $prpp7 + [1,0] *
1052 // this is approximate, but will do
1053 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1056 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1057 $prpp12 = $prpp3 + v1[0] *
1058 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1059 $prp_r8 = prop_main_th;
1060 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1062 $prpp5 = [ $prpp12[0] - $prp_r5,
1063 $prpp3[1] - prop_prong_h + $prp_r5 ];
1064 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1065 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1066 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1067 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1072 module PropProfile(gamma, cut=0, rot=0){
1073 PropProfileAssignments(gamma){
1075 //#circleat($prpp3,1);
1076 //#circleat($prpp12,1);
1083 polygon([[-20,-0], [20,20], [0,0]]);
1085 rectfromto($prpp6, $prpp9);
1086 translate($prpp5) intersection(){
1088 polygon([[-10,-10], [0,0], [10,0]]);
1090 rectfromto($prpp12 + [0,-0.1], $prpp3);
1093 circleat($prpp1, $prp_r1);
1094 rectfromto($prpp12 + [0,-0.1], $prpp3);
1098 rotate([0,0, rot*-$prp_theta]){
1100 extra = cut ? prop_recess_slop : 0;
1101 rectfromto($prpp6, $prpp9);
1102 circleat($prpp11, $prp_r11 + extra);
1103 circleat($prpp10, $prp_r10 + extra);
1109 module PropAggregateProfile(){
1110 for (angle = prop_angles)
1111 PropProfile(angle, 0,0);
1114 module Prop(){ ////toplevel
1115 hw = prop_main_width/2;
1117 PropAggregateProfile();
1120 module Case(){ ////toplevel
1125 // ledge (fixed keeper)
1126 Flip_rhs(1-keeper_side) intersection(){
1128 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1131 // outline of the whole case, to stop it protruding
1132 translate([0,0, -25])
1133 linear_extrude(height = 50)
1136 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1140 HingePortion(hex20, hex21) HingeBaseProfile();
1142 // buildout for prop recess
1143 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1144 linextr(case_bottom_z, epp2i[1])
1147 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1149 r = epp2o[0] - prcp2[0]);
1154 Flip_rhs(keeper_side)
1155 translate([0, -phone_cnr_rad, 0])
1157 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1160 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1161 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1165 RearCameraAperture();
1167 // struts (invisible, because they're buried in the case)
1168 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1173 if (!($button_leg_only && enable_support))
1175 translate([0,0,-10])
1176 linear_extrude(height= 20)
1177 ButtonPlan($button_l, 0,1);
1178 if ($button_leg_only)
1180 translate([phone_width/2, -400, kppe[1]])
1181 mirror([1-abs($rhsflip - keeper_side),0,0])
1182 cube([400, 800, 50]);
1183 if (enable_support && !$button_suppress_over_keeper)
1185 translate([-400, -400, kppd[1]])
1187 cube([800,800,100]);
1189 translate([0,0, -bppR[0]])
1190 linear_extrude(height= 20)
1191 ButtonPlan($button_l, 1,1);
1196 // apertures along top edge
1197 CaseAperture(jack_pos, jack_dia, 8);
1199 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1201 OrdinaryRearApertures();
1205 // gaps for the lid's hinge arms
1206 HingePortion(hex20 - hinge_x_arms_gap,
1207 hex21 + hinge_x_arms_gap)
1210 circle(r= hinge_r_arms_gap, $fn= 8);
1213 // screw holes in the hinge arms
1217 CatchPortion(catch_side_gap*2, epp4[1])
1222 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1223 rotate([0, ly_theta, 0])
1225 LanyardCutout(lanyard_channel_len);
1229 translate([prop_x_pos,0,0])
1232 linextr(-prop_recess_hw, +prop_recess_hw)
1234 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1235 circleat(prcp1 + 20*d,
1241 module LidAdhocMultiprintFrame(phase){
1242 if (led_window_style >= 3) {
1243 AdhocMultiprintFrame(phase, lpp13[1], -1);
1247 module LidAroundEdges(){
1248 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1252 module Lid(){ ////toplevel
1253 skew_centre = [0, lpp11[0], lpp11[1]];
1260 translate(skew_centre)
1261 multmatrix([[ 1, 0, 0, 0 ],
1262 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1265 translate(-skew_centre)
1267 LidEdgeFoldClearanceProfile();
1274 translate([0,0,-10])
1275 linear_extrude(height= 20)
1276 ButtonPlan($button_l, 1,0);
1279 translate([0,0,-100])
1280 linear_extrude(height= 200)
1281 ButtonCoverProfile();
1283 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1284 - lid_buttoncover_reinf))
1292 HingePortion(hex20, hex21) {
1298 CatchPortion(0, lpp12[1])
1299 CatchCatchProfile();
1301 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1303 // screw holes in the hinge arms
1307 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1310 linextr(-prop_recess_hw, +prop_recess_hw)
1312 for (pa = prop_angles)
1313 PropProfile(pa, 1,1);
1315 // notification led aperture
1316 if (led_window_style)
1317 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1318 translate([0,0,-10])
1319 cylinder(r=nla_r0, h=20);
1320 if (led_window_style >= 2)
1321 translate([0,0, -nla_t])
1322 cylinder(r=nla_r2, height=20);
1327 LidAdhocMultiprintFrame(1);
1330 module HingeLever(){ ////toplevel
1332 // outer body, positive
1333 HingePortion(hex22, hex22 + phone_width/2)
1334 HingeLeverOuterProfile();
1336 // space for the screws
1337 HingePortion(hex26, hex24)
1338 HingeLeverInnerProfile();
1340 // recesses for the nuts
1341 HingePortion(hex23, hex26+1)
1342 HingeLeverNutProfile();
1344 // bores for the screws
1347 // space for the charging cable
1349 Flip_hinge() MicroUSB();
1353 module LidWindow(){ ////toplevel
1354 translate([led_pos[0], -led_pos[1], lpp13[1]])
1356 cylinder(r= nla_r1, h=nla_t);
1357 LidAdhocMultiprintFrame(0);
1360 module LidWindowPrint(){ ////toplevel
1365 module DemoLidWindowSelect(){
1366 translate([led_pos[0], led_pos[1], -100]) {
1367 translate([0, -30, 0]) cube([400, 400, 200]);
1371 module DemoLidWindow(){ ////toplevel
1374 translate([0,40,0]){
1375 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1376 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1380 module HingeLeverPrint(){ ////toplevel
1382 translate([-phone_width/2, phone_height, 0])
1386 module TestSelectLength(){
1387 translate([-30, -200, -20])
1388 cube([30 + 15, 250, 40]);
1391 module TestLength(){ ////toplevel
1398 module TestLengthRight(){ ////toplevel
1406 module TestSelectWidth(){
1407 translate([-30, -(phone_height - 25), -20])
1409 cube([200, 50, 40]);
1412 module TestWidth(){ ////toplevel
1419 module TestLidWidthPrint(){ ////toplevel
1420 rotate([0,180.0]) intersection(){
1426 module TestSelectRearAperture(){
1429 translate([20, 0,0])
1430 cube([42, 2, 1], center=true);
1434 module TestSelectCamera(){
1436 TestSelectRearAperture()
1437 RearCameraAperture();
1438 cube([0.1, 50, 0.1]);
1442 module TestSelectOrdinaryRearApertures(){
1443 TestSelectRearAperture()
1444 OrdinaryRearApertures();
1447 module TestCamera(){ ////toplevel
1454 module TestLidByCamera(){ ////toplevel
1461 module TestLidByCameraPrint(){ ////toplevel
1462 rotate([180,0,0]) TestLidByCamera();
1465 module DemoByCamera(){ ////toplevel
1466 color("blue") TestLidByCamera();
1467 color("red") TestCamera();
1470 module OneKeeper(){ ////toplevel
1471 translate([0, -phone_cnr_rad, 0])
1473 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1477 module OneKeeperPrint(){ ////toplevel
1482 module LidPrint(){ ////toplevel
1487 module TestSelectFrame(){
1488 include = [1,-1] * (epp2i[0] + 4);
1491 cube(1000, center=true);
1492 translate([0,0, -100])
1493 linear_extrude(height=200)
1494 rectfromto(include, inside_br - include);
1498 module TestSelectLidFrame(){
1500 translate([led_pos[0], -led_pos[1], -50])
1501 cylinder(r= nla_r2+3, h=100);
1504 module TestFrameCase(){ ////toplevel
1510 TestSelectOrdinaryRearApertures();
1515 module TestSelectTopApertures(){
1516 translate([-100, -35, -100])
1517 cube([400, 100, 200]);
1518 LidAdhocMultiprintFrame(0);
1519 LidAdhocMultiprintFrame(1);
1522 module TestTopApertures(){ ////toplevel
1526 TestSelectTopApertures();
1530 module TestLidTopAperturesPrint(){ ////toplevel
1531 rotate([0,180,0]) intersection(){
1533 TestSelectLidFrame();
1534 TestSelectTopApertures();
1538 module TestLidWindowTopAperturesPrint(){ ////toplevel
1539 rotate([0,180,0]) intersection(){
1541 TestSelectTopApertures();
1545 module TestFrameLidPrint(){ ////toplevel
1546 rotate([0,180,0]) intersection(){
1548 TestSelectLidFrame();
1552 module ButtonPlanForDemo(z, deep, cut){
1554 ButtonPlan(8, deep, cut);
1557 module HingeScrews(){
1558 Flip_rhs() Flip_bot(1){
1559 for (c= [ hppT, hppB ])
1564 translate([0,0,-.2])
1565 cylinder( r= hingescrew_shaft_dia/2,
1566 h = hingescrew_shaft_len+0.2 );
1568 translate([0,0,+.1])
1569 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1574 module DemoPropAngleSelect(c){
1575 color(c) difference(){
1576 union(){ children(); }
1577 translate([ prop_x_pos, -400, -200 ])
1578 cube([ 400,800,400 ]);
1582 module DemoPropAngle(ang){
1583 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1584 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1592 DemoPropAngleSelect("red") Case();
1595 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1596 PropProfileAssignments(ang) {
1598 rotate([-$prp_theta, 0, 0])
1599 translate([0, $prpp1[0], -$prpp1[1]])
1605 translate([0,0, -hp_k*2])
1606 DemoPropAngleSelect("blue")
1610 module DemoPropAngles(){ ////toplevel
1611 for (i=[0 : len(prop_angles)-1])
1612 translate(i * [0, -100, 100])
1613 DemoPropAngle(prop_angles[i]);
1616 module DemoHingeAngle(ang1,ang2){
1617 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1618 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1629 color("blue") intersection(){
1632 translate([bppJ[0], -400, -200])
1634 cube([400, 800, 400]);
1635 translate([10, -400, -200])
1636 cube([10, 800, 400]);
1641 module DemoHingeAngles(){ ////toplevel
1642 angles = [ 0, 4, 8, 12 ];
1643 echo("angles",angles);
1644 for (i=[0 : len(angles)-1]) {
1645 translate(i * [0, 0, 30]) {
1646 DemoHingeAngle(0,angles[i]);
1647 translate([0, 200, 0])
1648 DemoHingeAngle(angles[i],0);
1653 module DemoSelectAdhocLeftRight(right=0) {
1654 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1655 mirror([1-right, 0,0])
1656 cube([400, 800, 200]);
1659 module DemoLeft(){ ////toplevel
1660 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1661 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1664 module DemoFrame(){ ////toplevel
1665 color("red") TestFrameCase();
1666 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1667 color("black") HingeScrews();
1671 module DemoLanyardCutout(){ ////toplevel
1675 module DemoHingedFrame(){ ///toplevel
1676 color("red") TestFrameCase();
1677 translate([0,0, -2*hp_k])
1678 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1681 color("orange") HingeLever();
1682 color("black") HingeScrews();
1686 module DemoHinge(){ ////toplevel
1687 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1689 translate([0,0, -hp_k*3])
1694 module DemoProfiles(){ ////toplevel
1698 translate([0,0,-1]) color("black") KeeperProfile(1);
1701 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1702 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1703 translate([0, ly_q_z]){
1704 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1705 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1709 translate([0,0,-5]) color("white") translate(epp2i)
1711 rectfromto([-15, 0],
1712 [+15, -max_case_bottom_edge_thickness]);
1715 LanyardMainChannelProfile();
1716 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1717 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1724 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1726 color("blue") ButtonCoverProfile();
1728 rectfromto(bppQ, demopoint_QR);
1729 rectfromto(bppR, demopoint_QR);
1733 translate([-20,0]) {
1734 color("black") ButtonPlanForDemo(-2, 0,1);
1735 color("red" ) ButtonPlanForDemo(-4, 1,1);
1736 color("blue") ButtonPlanForDemo(-6, 1,0);
1739 translate([0, -30]) {
1742 color("blue") HingeLidProfile();
1743 color("red") HingeBaseProfile();
1744 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1748 translate([-30, -60 + 30*f]) {
1749 translate([0,0,-4]) EdgeProfile();
1750 %translate([0,0,-10]) HingeBaseProfile();
1751 translate([0,-2] * f * hp_k) {
1752 translate([0,0,-4]) LidEdgeProfile();
1753 %translate([0,0,-10]) %HingeLidProfile();
1755 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1756 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1757 translate([0,0,0]) color("red") difference(){
1758 HingeLeverOuterProfile();
1759 HingeLeverInnerProfile();
1761 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1766 translate([20,-30]) {
1769 //translate([0,0,1]) CatchCutProfile();
1770 translate([0,0,+1]) color("red")
1771 difference(){ EdgeProfile(); CatchCutProfile(); }
1772 color("blue") CatchCatchProfile();
1775 translate([40,-30]) {
1779 PropProfile(10, 1, 0);
1784 translate([60,-30]) {
1785 PropAggregateProfile();