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;
66 foldover_lever_gap = 0.50;
68 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
69 hingescrew_shaft_len = 12;
70 hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
71 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
72 hingescrew_head_th = 1.38 + 0.75;
73 hingescrew_head_dia = 3.92;
74 lever_cover_th = 0.75;
81 buttonishleg_default_l_is_fudge = 10;
83 strut_min_at_end = 1.5;
86 hinge_x_postscrew_gap = 0.75;
87 hinge_x_arms_gap = 0.35;
88 hinge_r_arms_gap = 0.55;
90 rearspeaker_gap = [ 1.0, 1.0 ]; // each side
92 // ---------- calculated ----------
94 phone_width = (phone + bumper*2)[0];
95 phone_height = (phone + bumper*2)[1];
97 inside_br = [phone_width, -phone_height];
99 //echo(camera_pos_tl + bumper,
100 // camera_pos_br + bumper);
102 // ----- could be changed -----
103 lid_buttoncover_gap = lid_gap_x;
104 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
106 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
108 //lid_lip_overlap_width xxx bad name = ;
109 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
112 epp1 = [0, -phone_edge_thick];
113 epp2i = epp1 + phone_backside_slope_thick * [ phone_backside_slope_inner, -1 ];
114 epp2o = epp1 + phone_backside_slope_thick * [ phone_backside_slope_outer, -1 ];
115 epp3 = epp2i + [10, 0];
116 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
117 epp4 = epp5 + [-1,0] * case_th_side;
120 kppd = kppe + [1,0] * keeper_inner_width;
121 kppc = kppd + [0,1] * keeper_th_z;
122 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
123 kppf = kppe - [0,1] * keeper_inner_height;
124 kppa = [ kppb[0], kppf[1] ];
126 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
127 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
129 lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
131 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
132 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
136 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
137 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
138 bppS = [ epp1[0], bppR[1] ];
139 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
140 bppP = bppQ + [0,1] * lid_buttoncover_gap;
141 bppO = [ bppN[0], bppP[1] ];
142 bppL = lpp10 + [5,0];
143 bppK = [ bppL[0], bppN[1] ];
144 bppJ = [ bppN[0], bppL[1] ];
147 hp_rn = hingescrew_nut_dia/2;
148 hp_r2_min = hp_rn + lever_cover_th;
149 hp_rs = hingescrew_shaft_dia/2;
150 hp_r1_min = hp_rs + hingemount_th;
152 hp_r1 = max(hp_r1_min, hp_r2_min);
156 hppS = epp2o + [0,-1] * case_th_bottom;
157 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
159 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
160 0.5 * (hppU + hppS)[1] ];
161 hppT = [ hppM[0], hppU[1] - hp_r1 ];
162 hppB = hppT + [0,-1] * hp_k;
164 // hinge elevation x coords
166 hingescrew_portion_len =
167 0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
169 hex20 = max(epp2o[0],
171 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
172 hex21 = hex20 + hingescrew_portion_len;
173 hex22 = hex21 - hinge_x_gap;
174 hex23 = hex22 + hingescrew_portion_len;
175 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
176 echo(hex20, hex21, hex22, hex23, hex24);
177 echo(hingescrew_portion_len);
179 // ---------- modules ----------
181 module KeeperProfile(slant=0){
182 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
183 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
186 module EdgeProfile(){
189 translate(epp3) square(case_th_bottom*2, center=true);
190 circleat(epp2o, r=case_th_bottom);
191 circleat(epp1, r=case_th_side);
192 rectfromto(epp0, epp4);
194 polygon([ epp5 + [0,10],
201 module LidEdgeProfile(){
210 circleat(lpp12, r=lp_r12);
211 rectfromto( lpp12 + [-10, 0],
212 lpp12 + [+10, +10] );
216 module ButtonCoverProfile(){
218 polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
226 module ButtonPlan(l, deep, cut){
228 (cut ? 0 : lid_buttoncover_gap);
231 (deep ? lid_buttoncover_overlap : 0);
233 C = [0,0]; // by definition
237 B0 = C + [0,-1] * button_cutout_depth;
238 B1 = B0 + [0,1] * epsilon;
240 r0 = 0.5 * (T[1] - B0[1]);
241 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
242 H = A + [0,-1] * delta;
248 E1 = E0 + [1,0] * epsilon;
250 I0 = [ E0[0], H[1] ];
251 I1 = [ E1[0], H[1] ];
254 for (m=[0,1]) mirror([m,0])
255 circleat(H, r0 - epsilon);
257 for (m=[0,1]) mirror([m,0]) {
267 circleat(D, r0 + epsilon);
272 module Flip_rhs(yn=[0,1]) {
274 translate([phone_width/2, 0, 0])
275 mirror([$rhsflip,0,0])
276 translate([-phone_width/2, 0, 0])
281 module Flip_bot(yn=[0,1]) {
283 translate([0, -phone_height/2, 0])
284 mirror([0, $botflip, 0])
285 translate([0, phone_height/2, 0])
290 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
293 translate([0, -phone_cnr_rad, 0])
295 linear_extrude(height = phone_height - phone_cnr_rad*2)
299 Flip_rhs() Flip_bot() {
300 translate([+1,-1] * phone_cnr_rad)
305 translate([-1,0] * phone_cnr_rad)
307 rectfromto([0,-20],[10,20]);
309 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
315 translate([ phone_width - phone_cnr_rad, 0,0 ])
317 linear_extrude(height = phone_width - phone_cnr_rad*2)
321 translate([0,0, fill_zstart])
322 mirror([0,0, fill_downwards])
323 linear_extrude(height = fill_th)
324 rectfromto([+1,-1] * phone_cnr_rad,
325 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
328 module CaseAperture(pos, dia, $fn) {
330 translate([ pos[0] + bumper[0],
333 rotate([-90, theta, 0])
334 cylinder(r = dia/2 / cos(theta),
338 module SideButton(y, y_ref_sign, l){
340 // +1 measured from top of actual phone to top of button
341 // -1 measured from bottom of actual phone to bottom of button
342 // 0 y is centre of button in coordinate system
344 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
345 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
348 translate([0, eff_y, 0])
352 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
353 $button_leg_only = true;
354 SideButton(y, y_ref_sign, l) children();
358 Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
359 Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
360 Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
361 Flip_rhs( ) LidButtonishLeg(20, -1) children();
362 // Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
365 module Struts(x_start, z_min, th){
366 // if th is negative, starts at z_min and works towards -ve z
367 // and object should then be printed other way up
368 for (i= [1 : 1 : case_struts_count]) {
372 mirror([0,0, th<0 ? 1 : 0])
374 -phone_height * i / (case_struts_count+1),
375 case_struts_solid_below])
376 linear_extrude(height= abs(th)
377 -(case_struts_solid_below+case_struts_solid_above))
378 rectfromto([ x_start, -0.5 * case_struts_width ],
379 [ phone_width - x_start, +0.5 * case_struts_width ]);
383 module OrdinaryRearAperture(rhs,bot, pos){
384 Flip_rhs(rhs) Flip_bot(bot)
387 translate(pos + bumper)
395 linextr(-epp2i[0], 60)
396 translate([0.5 * phone_width, 0, 0])
397 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
398 [+microusb_width/2, epp0[1] + -microusb_above]);
402 module OrdinaryRearApertures(){
404 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
405 rectfromto(-rearspeaker_gap,
406 rearspeaker_size + rearspeaker_gap);
408 // finger hole to remove phone
409 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
411 scale(fingerpushhole_dias)
415 module RearCameraAperture(){
418 linear_extrude(height = 20)
421 rectfromto(camera_pos_tl, camera_pos_br);
424 module HingeLidProfile(){
426 circleat(hppT, hp_r1);
427 circleat(lpp12, lp_r12);
435 module HingeBaseProfile(){
438 circleat(hppB, hp_r1);
439 circleat(epp2o, case_th_bottom);
440 circleat(hppB + [10,0], hp_r1);
442 polygon([epp5, epp1, epp2i, epp3, bppL]);
446 module HingeLeverOuterProfile(){
448 circleat(hppT, hp_r2);
449 circleat(hppB, hp_r2);
453 module HingeLeverInnerProfile(){
454 for (c = [hppT, hppB]) {
459 circleat(hppB, hp_rn);
464 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
465 translate(hinge_origin)
467 translate(-hinge_origin)
471 module HingePortion(x0,x1){
472 Flip_rhs() Flip_bot(1)
476 linear_extrude(height=x1-x0)
481 AroundEdges(epp3[1], case_th_bottom, 1)
485 module Case(){ ////toplevel
490 // ledge (fixed keeper)
493 linear_extrude(height = phone_height + phone_cnr_rad * 2)
496 // outline of the whole case, to stop it protruding
497 translate([0,0, -25])
498 linear_extrude(height = 50)
500 // Flip_rhs() // actually, we only care about the LH
502 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
506 HingePortion(hex20, hex21) HingeBaseProfile();
511 translate([0, -phone_cnr_rad, 0])
513 linear_extrude(height = phone_height + phone_cnr_rad * 2)
516 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
517 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
521 RearCameraAperture();
523 // struts (invisible, because they're buried in the case)
524 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
531 linear_extrude(height= 20)
532 ButtonPlan($button_l, 0,1);
533 if ($button_leg_only)
535 translate([phone_width/2, -400, kppe[1]])
536 mirror([$rhsflip,0,0]) cube([400, 800, 50]);
538 translate([0,0, -bppR[0]])
539 linear_extrude(height= 20)
540 ButtonPlan($button_l, 1,1);
544 // apertures along top edge
545 CaseAperture(jack_pos, jack_dia, 8);
547 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
549 OrdinaryRearApertures();
553 // gaps for the lid's hinge arms
554 HingePortion(hex20 - hinge_x_arms_gap,
555 hex21 + hinge_x_arms_gap)
558 circle(r= hinge_r_arms_gap, $fn= 8);
561 // screw holes in the hinge arms
566 module Lid(){ ////toplevel
569 AroundEdges(lpp10[1], lpp13[1] - lpp10[1], 0)
577 linear_extrude(height= 20)
578 ButtonPlan($button_l, 1,0);
580 translate([0,0,-100])
581 linear_extrude(height= 200)
582 ButtonCoverProfile();
587 HingePortion(hex20, hex21) HingeLidProfile();
589 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
591 // screw holes in the hinge arms
596 module HingeLever(){ ////toplevel
598 // outer body, positive
599 HingePortion(hex22, hex22 + phone_width/2)
600 HingeLeverOuterProfile();
602 // space for the screws
603 HingePortion(hex23, hex24)
604 HingeLeverInnerProfile();
606 // bores for the screws
609 // space for the charging cable
611 Flip_hinge() MicroUSB();
615 module HingeLeverPrint(){ ////toplevel
620 module TestSelectLength(){
621 translate([-30, -200, -20])
622 cube([30 + 15, 250, 40]);
625 module TestLength(){ ////toplevel
632 module TestLengthRight(){ ////toplevel
640 module TestSelectWidth(){
641 translate([-30, -(phone_height - 25), -20])
646 module TestWidth(){ ////toplevel
653 module TestLidWidthPrint(){ ////toplevel
654 rotate([0,180.0]) intersection(){
660 module TestSelectRearAperture(){
664 cube([42, 2, 1], center=true);
668 module TestSelectCamera(){
670 TestSelectRearAperture()
671 RearCameraAperture();
672 cube([0.1, 50, 0.1]);
676 module TestSelectOrdinaryRearApertures(){
677 TestSelectRearAperture()
678 OrdinaryRearApertures();
681 module TestCamera(){ ////toplevel
688 module TestLidByCamera(){ ////toplevel
695 module TestLidByCameraPrint(){ ////toplevel
696 rotate([180,0,0]) TestLidByCamera();
699 module DemoByCamera(){ ////toplevel
700 color("blue") TestLidByCamera();
701 color("red") TestCamera();
704 module OneKeeper(){ ////toplevel
705 translate([0, -phone_cnr_rad, 0])
707 linear_extrude(height = phone_height - phone_cnr_rad * 2)
711 module OneKeeperPrint(){ ////toplevel
716 module LidPrint(){ ////toplevel
721 module TestSelectFrame(){
722 include = [1,-1] * (epp2i[0] + 4);
725 cube(1000, center=true);
726 translate([0,0, -100])
727 linear_extrude(height=200)
728 rectfromto(include, inside_br - include);
732 module TestFrameCase(){ ////toplevel
738 TestSelectOrdinaryRearApertures();
743 module TestFrameLidPrint(){ ////toplevel
744 rotate([0,180,0]) intersection(){
750 module Keeper(){ ////toplevel
755 module ButtonPlanForDemo(z, deep, cut){
757 ButtonPlan(8, deep, cut);
760 module HingeScrews(){
761 Flip_rhs() Flip_bot(1){
762 for (c= [ hppT, hppB ])
768 cylinder( r= hingescrew_shaft_dia/2,
769 h = hingescrew_shaft_len+0.2 );
772 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
777 module DemoFrame(){ ////toplevel
778 color("red") TestFrameCase();
779 color("blue") intersection(){ Lid(); TestSelectFrame(); }
780 color("black") HingeScrews();
784 module DemoHingedFrame(){ ///toplevel
785 color("red") TestFrameCase();
786 translate([0,0, -2*hp_k])
787 color("blue") intersection(){ Lid(); TestSelectFrame(); }
790 color("orange") HingeLever();
791 color("black") HingeScrews();
795 module DemoHinge(){ ////toplevel
797 translate([0,0, -hp_k*3])
801 module DemoProfiles(){ ////toplevel
805 translate([0,0,-1]) color("black") KeeperProfile(1);
811 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
813 color("blue") ButtonCoverProfile();
815 rectfromto(bppQ, demopoint_QR);
816 rectfromto(bppR, demopoint_QR);
821 color("black") ButtonPlanForDemo(-2, 0,1);
822 color("red" ) ButtonPlanForDemo(-4, 1,1);
823 color("blue") ButtonPlanForDemo(-6, 1,0);
826 translate([0, -30]) {
829 color("blue") HingeLidProfile();
830 color("red") HingeBaseProfile();
831 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
832 color("orange") translate([0,0,-1]) HingeLeverInnerProfile();