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.
14 // 3. use "make" to generate the necessary files:
16 // make -j8 fairphone-case.auto.scads `for f in \
21 // ; do echo fairphone-case,$f.auto.stl; done`
23 // 4. Print them. Case and OneKeeperPrint should probably be
26 // 5. Assemble the hinge. After placing the parts in the appropirate
27 // relative placement:
29 // Use long bit of wire to ensure holes are lined up and proper
30 // Cut four short bits of wire, using above as a guage
32 // Push two short bits into two holes on same side
33 // Use long bit of wire to ensure properly in holes
34 // Keep that side up so they don't fall out!
36 // For each of the two holes
37 // Use 20-30cm hunk of 2.85mm PLA
38 // Use gas flame to melt end until it catches fire (!)
39 // Remove from flame, wave to extinguish, and quickly:
40 // Dab end onto where hole is
41 // As it congeals, use sidecutters to cut off by hole
43 // Repeat for two holes on other side
44 // When cool, file down rough edges
48 // - To put the phone in, drop its RH side into the RH side of
49 // the case. Then feed the keeper through the small hole.
50 // Feed it right through.
52 // - The optional prop can be used to prop the phone up (in
53 // portrait orientation only right now). See
54 // openscad fairphone-case,DemoPropAngles.auto.scad
58 // It might well be possible to adapt this file for other phones.
59 // If you do, let me know how you get on.
62 // AUTHORSHIP, COPYRIGHT, LICENCE, AND LACK OF WARRANTY
64 // Copyright (C) 2018-2022 Ian Jackson.
66 // This program for generating a 3D model is free software: you can
67 // redistribute it and/or modify it under the terms of the GNU
68 // General Public License as published by the Free Software
69 // Foundation, either version 3 of the License, or (at your option)
72 // This program is distributed in the hope that it will be useful,
73 // but WITHOUT ANY WARRANTY; without even the implied warranty of
74 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
75 // GNU General Public License for more details.
77 // You should have received a copy of the GNU General Public
78 // License along with this program. If not, see
79 // <http://www.gnu.org/licenses/>.
81 // In particular DO NOT BLAME ME IF THIS CASE DOES NOT ADEQUATELY
82 // PROTECT YOUR PHONE ! It is your responsibility to decide whether
83 // this case will meet your needs.
88 phone = [ 75.86, 162.0 ];
90 prop_buildout_less = 3;
92 prop_angles = [ 15, 30, 45, 60 ];
94 bumper = [ 0.250, -0.025 ];
95 // ^ One side. Overall size is increased by twice this.
96 // If no bumpers, is the gap around the phone.
100 led_window_style = 0;
102 // 1: simply an opening
103 // 2: opening with separate cover model, for printing in clear (two colour)
104 // 3: like 2 but one-layer window for ad-hoc multi-colour
106 initial_layer_thick = 0.400; // ^ needed for mode 3 only
107 initial_layer_width = 0.750; // ^ needed for mode 3 only
108 multicolour_gap = 0.15; // each side
110 phone_cnr_rad = 7.0; // actuall 8.mumble, but smaller is fine
111 phone_rim_depth = 0.01; // includes allowance for a screen protector
113 button_cutout_depth = 9;
115 phone_edge_thick = 11.25;
117 camera_pos_tl = [ 5.600, 5.750 ]; // from tl corner (as seen from back)
118 camera_edge_rad = 9.750 + 0.700;
119 camera_sz = 32.920 + .750 + 1.000;
121 // this is disabled, FP4 doesn't have one
122 jack_pos = [ 13.83, 8.485 ];
123 jack_dia = 10.64 + .5; // some jack I had lying around
125 // this led stuff, is irrelevant, we have disabled it as it doesn't have one
126 led_pos = []; // [ 13.98, 10.00 ];
128 led_window_ledge = 0.75; // each side
130 noisecancelmic_pos = [ 15.08 + .720, 4.35 ]; // from rhs, from top edge
131 noisecancelmic_dia = 4.00;
133 mainmic_pos = [ 21.0, 4.65 ]; // from lhs, from top edge
136 lhshole_pos = [ phone[1]/2 + 0.40, 4.35 ];
138 fingerpushhole_dias = [];
139 //fingerpushhole_dias = [ 15, 18 ]; // this is for testing
141 lanyard_half_dia = 1.15;
142 lanyard_entry_rel_breadth = 2;
143 lanyard_channel_len = 8;
144 //rearspeaker_pos_bl = [ 12.64, 18.72 ];
145 //rearspeaker_size = [ 3.76, 7.36 ];
147 bottomspeaker_size = [ 11.35, 1.90 ] + [1,1] * 0.5;
148 bottomspeaker_pos = [ 17.55, 5.17 ]; // from rhs, from top
150 microusb_above = 1.64 - 0.25;
151 microusb_below = 2.42;
152 microusb_width = 12.16 + 2.0 + 1.25;
154 case_th_bottom = 2.5;
159 lid_screen_gap_extra = .66;
161 case_struts_count = 6;
162 case_struts_solid_below = 1.00;
163 case_struts_solid_above = 0.75;
164 case_struts_width = 0.10;
168 keeper_inner_width = 2.75;
169 keeper_inner_height = 2.75;
170 keeper_slant_slope = 2; // larger means steeper
172 keeper_gap_z_top = 0.25;
173 keeper_gap_z_bot = 0.75;
175 keeper_gap_x_holes = 0.75;
176 keeper_fatter = 0.45;
177 keeper_fatter_hole = 1.20;
179 keeper_side = 0; // 0 = lhs; 1 = rhs
186 lid_edgepart_width = 5.0;
187 lid_buttoncover_thick = 1.3;
188 lid_buttoncover_reinf = 0.95;
191 foldover_lever_gap = 0.50;
193 // properties of the hinge fasteners
194 hingescrew_shaft_dia = 1.600 + 0.45; // beading wire
195 hingescrew_shaft_len = 10;
196 hingescrew_fasteners_extra_thick = 0.40;
197 // ^ amount of thread protruding if everything was completely nominal
198 // and we are using two nuts
199 hingescrew_nut_access_dia = 4.72 + 0.50;
200 // ^ washer is 4.72 dia
201 // also, want to get pliers or tiny spanner in to do up locknut
202 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
203 hingescrew_nut_thick = 1.93;
204 hingescrew_head_th = 1.38 + 0.75;
205 hingescrew_head_dia = 3.92;
207 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
209 lever_cover_th = 0.75;
211 hingemount_wd = 4.8725;
216 button_l_fudge = 4.4;
217 buttonishleg_default_l_is_fudge = 10;
219 hinge_base_slope = 1.5; // bigger is steeper
221 strut_min_at_end = 1.5;
224 hinge_x_postscrew_gap = 0.75;
225 hinge_x_arms_gap = 0.35;
226 hinge_r_arms_gap = 0.55;
227 hinge_over_nut_plate = -0.50; // bodge apropos slope
229 // there isn't one of these, speaker is by hinge
230 // rearspeaker_gap = [ 2.0, 2.0 ]; // each side
232 thumbrecess_depth = 1.3;
233 thumbrecess_width = 16.5;
234 thumbrecess_topcurve_r = 5.0;
236 prop_recess_under = 0.50;
237 prop_recess_slop = 0.200; // each side
242 prop_side_gap = 0.75; // each side
243 prop_lidrecess_behind = 0.75;
244 prop_caserecess_behind = 0.75;
245 prop_caserecess_taper = 0.45; // one side only
247 prop_prong_heel_slope = 0.5;
249 lid_fold_clearance_antislop = 0.5;
251 $button_leg_only = false;
252 $suppress_forward_holes = false;
253 $suppress_hinge = false;
255 // ---------- calculated ----------
257 phone_total_thick = phone_edge_thick;
259 phone_width = (phone + bumper*2)[0];
260 phone_height = (phone + bumper*2)[1];
262 inside_br = [phone_width, -phone_height];
264 prop_prong_h = prop_main_th;
266 //echo(camera_pos_tl + bumper,
267 // camera_pos_br + bumper);
269 // ----- could be changed -----
270 lid_buttoncover_gap = lid_gap_x;
271 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
273 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
275 //prop_nose_len = case_th_lid - prop_recess_under;
276 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
277 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
281 epp1 = [0, -phone_edge_thick];
282 epp2i = epp1; // conflated for FP4
284 epp3 = epp2i + [10, 0];
285 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
286 epp4 = epp5 + [-1,0] * case_th_side;
289 kppd = kppe + [1,0] * keeper_inner_width;
290 kppc = kppd + [0,1] * keeper_th_z;
291 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
292 kppf = kppe - [0,1] * keeper_inner_height;
293 kppa = [ kppb[0], kppf[1] ];
295 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
296 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
298 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
299 // exact x posn not very important; must extend past end of keeper
302 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
303 + lid_screen_gap_extra ];
304 // ^ beam theory says to maximise force before contact,
305 // the gap below the `beam' (the lid) must be 1/3
306 // the thickness (ie the lid thickness) if the beam
307 // is solid, or 1/2 if it has a top and bottom only.
308 // ours is mostly solid.
310 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
313 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
314 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
316 case_bottom_z = epp2o[1] - case_th_bottom;
320 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
321 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
322 bppS = [ epp1[0], bppR[1] ];
323 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
324 bppP = bppQ + [0,1] * lid_buttoncover_gap;
325 bppO = [ bppN[0], bppP[1] ];
326 bppL = lpp10 + [5,0];
327 bppK = [ bppL[0], bppN[1] ];
328 bppJ = [ bppN[0], bppL[1] ];
329 bppU = [ bppJ[0], lpp12[1] ];
333 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
335 // notification led aperture
337 nla_r0 = led_aperture/2;
338 nla_r1 = nla_r0 + led_window_ledge;
339 nla_r2 = nla_r1 + multicolour_gap;
341 led_window_style >= 3 ? initial_layer_thick :
342 led_window_style >= 2 ? led_window_ledge : 0;
346 hp_rn = hingescrew_nut_access_dia/2;
347 hp_r2_min = hp_rn + lever_cover_th;
348 hp_rs = hingescrew_shaft_dia/2;
349 hp_r1_min = hp_rs + hingemount_th;
351 hp_r1 = max(hp_r1_min, hp_r2_min);
355 hppS = epp2o + [0,-1] * case_th_bottom;
356 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
358 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
359 0.5 * (hppU + hppS)[1] ];
360 hppT = [ hppM[0], hppU[1] - hp_r1 ];
361 hppB = hppT + [0,-1] * hp_k;
363 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
364 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
365 hppE = [ hppE_x, hppE_y ];
367 // hinge elevation x coords
369 hex20 = max(epp2o[0],
371 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
372 hex21 = hex20 + hingemount_wd;
373 hex22 = hex21 + hinge_x_gap;
374 hex27 = hex20 + hingescrew_shaft_len;
375 hex24 = hex27 + hinge_x_postscrew_gap;
376 hex23 = hex27 - (hingescrew_nut_thick*2
377 + hingescrew_fasteners_extra_thick);
378 hex26 = hex23 + hingescrew_nut_thick * 2/3;
380 //echo(hex20, hex21, hex22, hex23, hex24);
381 //// 6, 10.8725, 10.9975, 13.74, 18.75
382 //module chk(act,exp) {
383 // if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
384 // else echo("ok", act);
387 //chk(hex21, 10.8725);
388 //chk(hex22, 10.9975);
392 lid_fold_clearance_skew =
393 (lpp10[1] - hppB[1]) /
394 (lpp10[0] - hppB[0]);
396 echo("SK",lid_fold_clearance_skew);
398 // thumb recess (used to be "catch" hence cpp*
400 cppA = epp4 + [thumbrecess_depth, 0];
401 cppB = [ cppA[0], epp1[1] ];
405 ly_r = lanyard_half_dia / 2;
409 ly_o = epp2i + 3 * ly_r * [0,1];
411 max_case_bottom_edge_thickness =
414 ly_q_z = -(ly_rc + ly_r);
415 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
417 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
419 // prop recess in case
421 prop_x_pos = phone_width/2;
423 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
425 prc_r1 = prop_end_dia/2;
426 prc_r3 = prc_r1 + prop_recess_slop;
428 prcp2 = [ epp4[0] + prop_buildout_less,
431 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
433 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
434 epp2i[1] - prc_r3 - prop_recess_under];
436 // prop recess in lid
438 prl_r10 = prop_end_dia/2;
439 prl_r10o = prl_r10 + prop_recess_slop;
441 prlp10 = lpp10 + [1,1] * prl_r10o
442 + [1,0] * prop_lidrecess_behind
443 + [0,1] * prop_recess_under;
448 $prpp11 = [0, prop_taper_len];
452 // ---------- modules ----------
454 module AdhocMultiprintFrame(phase, z0, zs) {
455 // from z0 to z0 + zs*layer
456 extra = phase * (initial_layer_width + multicolour_gap) + 5;
457 xextra = extra + -epp4[0];
458 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
459 yextra = extra + -epp4[0];
460 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
461 p0 = [ xrange[0], yrange[0] ];
462 p1 = [ xrange[1], yrange[1] ];
465 mirror([0,0, zs<0 ? 1 : 0])
466 linear_extrude(height= initial_layer_thick)
468 rectfromto(p0 - [1,1] * initial_layer_width,
469 p1 + [1,1] * initial_layer_width);
474 module KeeperProfile(fatter=0, slant=0, stubbier=0){
475 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
476 polygon([use_e + [+1,-1] * fatter,
477 kppd + [ 0,-1] * fatter - stubbier * [1,0],
478 kppc - stubbier * [1,0],
480 kppa + stubbier * [0,1],
481 kppf + [+1, 0] * fatter + stubbier * [0,1]
485 module EdgeProfile(){
488 translate(epp3) square(case_th_bottom*2, center=true);
489 circleat(epp2o, r=case_th_bottom);
490 circleat(epp1, r=case_th_side);
491 rectfromto(epp0, epp4);
493 polygon([ epp5 + [0,10],
499 module LanyardLanyardProfile(entry=false){
501 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
502 translate(xs * 0.5 * lanyard_half_dia * [1,0])
503 circle(r= lanyard_half_dia/2);
507 module LanyardCurveChannelProfile(){
508 translate([0, -ly_r])
509 LanyardLanyardProfile();
512 module LanyardEntryChannelProfile(){
513 LanyardLanyardProfile(true);
516 module LanyardMainChannelProfile(){
517 LanyardCurveChannelProfile();
519 square(center=true, ly_r * [6, 2]);
521 translate(ly_r * [3 * xs, -1])
526 module LanyardEntryOuterProfile(){
527 circleat([ly_re + ly_r, 0], ly_re);
530 module LanyardEntry(){
536 translate([d_x, 0, q_z]) {
539 rotate_extrude(convexity=10)
542 LanyardCurveChannelProfile();
550 linear_extrude(height=20)
552 LanyardEntryChannelProfile();
554 translate([0, ly_r*2, 0])
556 linear_extrude(height = ly_r*4){
558 rectfromto([d_x, q_z], [ly_r, 0]);
559 circleat([d_x, q_z], ly_rc);
563 translate([0,0,q_z]){
566 translate([0, oec_y, 0]){
568 translate(ly_re * [-1,0,-2])
569 cube(ly_re * [2,1,2]);
570 rotate_extrude(convexity=10)
571 LanyardEntryOuterProfile();
576 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
577 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
582 linear_extrude(height=20)
583 LanyardEntryOuterProfile();
588 module LanyardCutout(l){
590 linear_extrude(height=l)
592 LanyardMainChannelProfile();
595 translate(ee * l * [-1,0])
601 module LidEdgeProfile(){
612 circleat(lpp12, r=lp_r12);
613 rectfromto( lpp12 + [-10, 0],
614 lpp12 + [+10, +10] );
618 module LidEdgeFoldClearanceProfile(){
619 translate([-lid_fold_clearance_antislop, 0])
628 module ButtonCoverProfile(){
630 polygon(concat([ bppM, bppP, bppO, bppJ ],
631 (enable_support && !$button_suppress_over_keeper
632 ? [ bppU, bppV, bppW ] : []),
641 module ButtonPlan(l, deep, cut){
643 (cut ? 0 : lid_buttoncover_gap);
646 (deep ? lid_buttoncover_overlap : 0);
648 C = [0,0]; // by definition
652 B0 = C + [0,-1] * button_cutout_depth;
653 B1 = B0 + [0,1] * epsilon;
655 r0 = 0.5 * (T[1] - B0[1]);
656 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
657 H = A + [0,-1] * delta;
663 E1 = E0 + [1,0] * epsilon;
665 I0 = [ E0[0], H[1] ];
666 I1 = [ E1[0], H[1] ];
669 for (m=[0,1]) mirror([m,0])
670 circleat(H, r0 - epsilon);
672 for (m=[0,1]) mirror([m,0]) {
682 circleat(D, r0 + epsilon);
687 module ButtonCoverReinf(){ ////toplevel
690 linear_extrude(height=0.01)
692 ButtonCoverProfile();
693 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
696 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
697 circle(r= lid_buttoncover_reinf);
698 translate([-20,0]) square(40, center=true);
703 module ThumbRecessCutProfile(){
705 polygon([ cppA + [-10,0],
709 circleat(epp1, r=case_th_side);
713 module Flip_rhs(yn=[0,1]) {
715 translate([phone_width/2, 0, 0])
716 mirror([$rhsflip,0,0])
717 translate([-phone_width/2, 0, 0])
722 module Flip_bot(yn=[0,1]) {
724 translate([0, -phone_height/2, 0])
725 mirror([0, $botflip, 0])
726 translate([0, phone_height/2, 0])
731 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
734 translate([0, -phone_cnr_rad, 0])
736 linear_extrude(height = phone_height - phone_cnr_rad*2)
740 Flip_rhs() Flip_bot() {
741 translate([+1,-1] * phone_cnr_rad)
746 translate([-1,0] * phone_cnr_rad)
748 rectfromto([0,-20],[10,20]);
750 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
756 translate([ phone_width - phone_cnr_rad, 0,0 ])
758 linear_extrude(height = phone_width - phone_cnr_rad*2)
762 translate([0,0, fill_zstart])
763 mirror([0,0, fill_downwards])
764 linear_extrude(height = fill_th)
765 rectfromto([+1,-1] * phone_cnr_rad,
766 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
769 module CaseAperture(pos, dia, $fn, topbottom=0) {
771 translate([ bumper[0],
774 rotate([0,0, 90*topbottom])
775 translate([ pos[0] * (topbottom>0 ? -1 : +1), 0, -pos[1] ])
776 rotate([-90, theta, 0])
777 cylinder(r = dia/2 / cos(theta),
781 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
783 // +1 measured from top of actual phone to top of button
784 // -1 measured from bottom of actual phone to bottom of button
785 // 0 y is centre of button in coordinate system
787 $button_suppress_over_keeper= suppress_over_keeper;
788 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
789 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
792 translate([0, eff_y, 0])
796 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
797 $button_leg_only = true;
798 SideButton(y, y_ref_sign, l) children();
802 Flip_rhs(1) SideButton(30.320, +1, 22.960 ) children(); // volume
803 Flip_rhs(1) SideButton(64.220, +1, 14.500 ) children(); // power
804 Flip_rhs(1) LidButtonishLeg(14, -1) children();
805 Flip_rhs(0) LidButtonishLeg(21, -1) children();
806 Flip_rhs(0) LidButtonishLeg(38, +1) children();
807 Flip_rhs(0) LidButtonishLeg(14, +1) children();
810 module Struts(x_start, z_min, th){
811 // if th is negative, starts at z_min and works towards -ve z
812 // and object should then be printed other way up
813 for (i= [1 : 1 : case_struts_count]) {
817 mirror([0,0, th<0 ? 1 : 0])
819 -phone_height * i / (case_struts_count+1),
820 case_struts_solid_below])
821 linear_extrude(height= abs(th)
822 -(case_struts_solid_below+case_struts_solid_above))
823 rectfromto([ x_start, -0.5 * case_struts_width ],
824 [ phone_width - x_start, +0.5 * case_struts_width ]);
828 module OrdinaryRearAperture(rhs,bot, pos){
829 Flip_rhs(rhs) Flip_bot(bot)
832 translate(pos + bumper)
836 module MicroUSBEtc(){
840 linextr(-epp2i[0], 60)
841 translate([0.5 * phone_width, 0, 0])
842 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
843 [+microusb_width/2, epp0[1] + -microusb_above]);
847 module OrdinaryBottomEdgeApertures(){
849 CaseAperture(mainmic_pos, mainmic_dia, 8);
851 Flip_bot(1) Flip_rhs(1) {
852 linextr_y_xz(-epp2i[0], 60)
855 translate([ -bottomspeaker_pos[0], -bottomspeaker_pos[1] ] +
856 [ 0.5 * x * bottomspeaker_size[0] - bottomspeaker_size[1],
859 circle(r = bottomspeaker_size[1], $fn = 8);
864 module OrdinaryRearApertures(){
866 // OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
867 // rectfromto(-rearspeaker_gap,
868 // rearspeaker_size + rearspeaker_gap);
871 module NotInTestFrameRearApertures(){
872 // finger hole to remove phone
873 if (len(fingerpushhole_dias))
874 OrdinaryRearAperture(0,0, [ fingerpushhole_dias[0] + epp2i[0],
876 scale(fingerpushhole_dias)
880 module RearCameraAperture(){
884 hull() // there is some kind of bug if hull() is done in 2D here!
885 linear_extrude(height = 20)
888 translate(camera_pos_tl)
889 for (xy = [ [0,0], [0,1], [1,0] ]) {
891 camera_edge_rad * [1,1] +
892 xy * (camera_sz - camera_edge_rad * 2)
894 circle(r = camera_edge_rad);
898 module HingeLidProfile(){
900 circleat(hppT, hp_r1);
901 circleat(lpp12, lp_r12);
909 module HingeBaseProfile(){
912 circleat(hppB, hp_r1);
913 circleat(hppE, hp_r1);
914 circleat(epp2o, case_th_bottom);
915 circleat(hppB + [10,0], hp_r1);
917 polygon([epp5, epp1, epp3, bppL]);
921 module HingeLeverOuterProfile(){
923 circleat(hppT, hp_r2);
924 circleat(hppB, hp_r2);
928 module HingeLeverInnerProfile(){
930 c = s > 0 ? hppT : hppB;
932 mirror([0,0, s>0 ? 1 : 0])
933 rotate(s<0 ? -40 : 0)
942 module HingeLeverNutProfile(){
943 for (c= [hppB, hppT]) {
945 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
949 module Flip_hinge(doflip=1){
950 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
951 translate(hinge_origin)
952 rotate([doflip*180,0,0])
953 translate(-hinge_origin)
957 module HingePortion(x0,x1){
958 Flip_rhs() Flip_bot(1)
962 linear_extrude(height=x1-x0)
966 module ThumbRecessApply(ztop){
967 width = thumbrecess_width;
968 w = width + thumbrecess_topcurve_r*2 + 1;
969 translate([phone_width/2, 0,0]){
974 translate([0, 50, 0])
976 linear_extrude(height=100){
977 for (m=[0,1]) mirror([m,0,0]) {
979 translate([w/2, ztop - thumbrecess_topcurve_r])
980 circle(thumbrecess_topcurve_r);
981 translate([w/2, -50])
982 square(thumbrecess_topcurve_r*2, center=true);
991 AroundEdges(epp3[1], case_th_bottom, 1)
995 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
997 module PropProfileAssignments(gamma){
998 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
1000 p = phone_height + prlp10[0] - hppB[0];
1003 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
1005 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
1006 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
1008 $prp_theta = 90 - $prp_alpha;
1009 beta = 180 - $prp_alpha - gamma;
1012 //echo("abc", a,b,c);
1014 v1 = [ [ cos(psi), -sin(psi) ], // x
1015 [ sin(psi), cos(psi) ] ]; // y
1017 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1020 $prp_r11 = prop_main_th/2;
1022 $prpp1 = $prpp7 + [1,0] *
1023 // this is approximate, but will do
1024 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1027 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1028 $prpp12 = $prpp3 + v1[0] *
1029 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1030 $prp_r8 = prop_main_th;
1031 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1033 $prpp5 = [ $prpp12[0] - $prp_r5,
1034 $prpp3[1] - prop_prong_h + $prp_r5 ];
1035 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1036 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1037 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1038 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1043 module PropProfile(gamma, cut=0, rot=0){
1044 PropProfileAssignments(gamma){
1046 //#circleat($prpp3,1);
1047 //#circleat($prpp12,1);
1054 polygon([[-20,-0], [20,20], [0,0]]);
1056 rectfromto($prpp6, $prpp9);
1057 translate($prpp5) intersection(){
1059 polygon([[-10,-10], [0,0], [10,0]]);
1061 rectfromto($prpp12 + [0,-0.1], $prpp3);
1064 circleat($prpp1, $prp_r1);
1065 rectfromto($prpp12 + [0,-0.1], $prpp3);
1069 rotate([0,0, rot*-$prp_theta]){
1071 extra = cut ? prop_recess_slop : 0;
1072 rectfromto($prpp6, $prpp9);
1073 circleat($prpp11, $prp_r11 + extra);
1074 circleat($prpp10, $prp_r10 + extra);
1080 module PropAggregateProfile(){
1081 for (angle = prop_angles)
1082 PropProfile(angle, 0,0);
1085 module Prop(){ ////toplevel
1086 hw = prop_main_width/2;
1088 PropAggregateProfile();
1091 module Case(){ ////toplevel
1096 // ledge (fixed keeper)
1097 Flip_rhs(1-keeper_side) intersection(){
1099 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1100 KeeperProfile(fatter=0, slant=1);
1102 // outline of the whole case, to stop it protruding
1103 translate([0,0, -25])
1104 linear_extrude(height = 50)
1107 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1111 if (!$suppress_hinge)
1112 HingePortion(hex20, hex21) HingeBaseProfile();
1114 // buildout for prop recess
1115 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1116 linextr(case_bottom_z, epp2i[1])
1119 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1121 r = epp2o[0] - prcp2[0]);
1126 Flip_rhs(keeper_side)
1127 translate([0, -phone_cnr_rad, 0])
1129 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1131 KeeperProfile(fatter=keeper_fatter_hole);
1132 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1133 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1137 RearCameraAperture();
1139 // struts (invisible, because they're buried in the case)
1140 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1145 if (!($button_leg_only && enable_support))
1147 translate([0,0,-10])
1148 linear_extrude(height= 20)
1149 ButtonPlan($button_l, 0,1);
1150 if ($button_leg_only)
1152 translate([phone_width/2, -400, kppe[1]])
1153 mirror([1-abs($rhsflip - keeper_side),0,0])
1154 cube([400, 800, 50]);
1155 if (enable_support && !$button_suppress_over_keeper)
1157 translate([-400, -400, kppd[1]])
1159 cube([800,800,100]);
1161 translate([0,0, -bppR[0]])
1162 linear_extrude(height= 20)
1163 ButtonPlan($button_l, 1,1);
1168 // apertures along top edge
1169 if (!$suppress_forward_holes) {
1170 // CaseAperture(jack_pos, jack_dia, 8);
1172 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1174 CaseAperture(lhshole_pos, noisecancelmic_dia, 8, 1);
1176 OrdinaryBottomEdgeApertures();
1178 OrdinaryRearApertures();
1179 NotInTestFrameRearApertures();
1183 // gaps for the lid's hinge arms
1184 if (!$suppress_hinge) {
1185 HingePortion(hex20 - hinge_x_arms_gap,
1186 hex21 + hinge_x_arms_gap)
1189 circle(r= hinge_r_arms_gap, $fn= 8);
1192 // screw holes in the hinge arms
1197 ThumbRecessApply(epp4[1])
1198 ThumbRecessCutProfile();
1202 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1203 rotate([0, ly_theta, 0])
1205 LanyardCutout(lanyard_channel_len);
1209 translate([prop_x_pos,0,0])
1212 linextr(-prop_recess_hw, +prop_recess_hw)
1214 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1215 circleat(prcp1 + 20*d,
1221 module LidAdhocMultiprintFrame(phase){
1222 if (led_window_style >= 3) {
1223 AdhocMultiprintFrame(phase, lpp13[1], -1);
1227 module LidAroundEdges(){
1228 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1232 module Lid(){ ////toplevel
1233 skew_centre = [0, lpp11[0], lpp11[1]];
1240 translate(skew_centre)
1241 multmatrix([[ 1, 0, 0, 0 ],
1242 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1245 translate(-skew_centre)
1247 LidEdgeFoldClearanceProfile();
1254 translate([0,0,-10])
1255 linear_extrude(height= 20)
1256 ButtonPlan($button_l, 1,0);
1259 translate([0,0,-100])
1260 linear_extrude(height= 200)
1261 ButtonCoverProfile();
1263 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1264 - lid_buttoncover_reinf))
1272 HingePortion(hex20, hex21) {
1277 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1279 // screw holes in the hinge arms
1283 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1286 linextr(-prop_recess_hw, +prop_recess_hw)
1288 for (pa = prop_angles)
1289 PropProfile(pa, 1,1);
1291 // notification led aperture
1292 if (led_window_style)
1293 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1294 translate([0,0,-10])
1295 cylinder(r=nla_r0, h=20);
1296 if (led_window_style >= 2)
1297 translate([0,0, -nla_t])
1298 cylinder(r=nla_r2, height=20);
1303 LidAdhocMultiprintFrame(1);
1306 module HingeLever(){ ////toplevel
1308 // outer body, positive
1309 HingePortion(hex22, hex22 + phone_width/2)
1310 HingeLeverOuterProfile();
1312 // space for the screws
1313 // HingePortion(hex26, hex24)
1314 // HingeLeverInnerProfile();
1316 // recesses for the nuts
1317 // HingePortion(hex23, hex26+1)
1318 // HingeLeverNutProfile();
1320 // bores for the screws
1323 // space for the charging cable and speaker and micc apertures
1329 * ( (hex24 + hinge_over_nut_plate) -
1330 (phone_width/2 - microusb_width/2)
1332 / ( (epp0[1] - microusb_above)
1334 (hppB[1] - hp_r2) ),
1336 x * (epp0[1] - microusb_above)
1343 Flip_hinge() MicroUSBEtc();
1351 module LidWindow(){ ////toplevel
1352 translate([led_pos[0], -led_pos[1], lpp13[1]])
1354 cylinder(r= nla_r1, h=nla_t);
1355 LidAdhocMultiprintFrame(0);
1358 module LidWindowPrint(){ ////toplevel
1363 module DemoLidWindowSelect(){
1364 translate([led_pos[0], led_pos[1], -100]) {
1365 translate([0, -30, 0]) cube([400, 400, 200]);
1369 module DemoLidWindow(){ ////toplevel
1372 translate([0,40,0]){
1373 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1374 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1378 module HingeLeverPrint(){ ////toplevel
1380 translate([-phone_width/2, phone_height, 0])
1384 module TestSelectLength(){
1385 translate([-30, -200, -20])
1386 cube([30 + 15, 250, 40]);
1389 module TestLength(){ ////toplevel
1396 module TestLengthRight(){ ////toplevel
1404 module TestSelectWidth(){
1405 translate([-30, -(phone_height - 25), -20])
1407 cube([200, 50, 40]);
1410 module TestWidth(){ ////toplevel
1417 module TestLidWidthPrint(){ ////toplevel
1418 rotate([0,180.0]) intersection(){
1424 module TestSelectRearAperture(){
1427 translate([20, 0,0])
1428 cube([42, 2, 1], center=true);
1432 module TestSelectCamera(){
1434 TestSelectRearAperture()
1435 RearCameraAperture();
1436 cube([0.1, 50, 0.1]);
1440 module TestSelectOrdinaryRearApertures(){
1441 TestSelectRearAperture()
1442 OrdinaryRearApertures();
1445 module TestCamera(){ ////toplevel
1452 module TestLidByCamera(){ ////toplevel
1459 module TestLidByCameraPrint(){ ////toplevel
1460 rotate([180,0,0]) TestLidByCamera();
1463 module DemoByCamera(){ ////toplevel
1464 color("blue") TestLidByCamera();
1465 color("red") TestCamera();
1468 module OneKeeper(){ ////toplevel
1469 translate([0, -phone_cnr_rad, 0])
1471 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1472 KeeperProfile(fatter=keeper_fatter);
1475 module OneKeeperPrint(){ ////toplevel
1480 module LidPrint(){ ////toplevel
1485 module TestSelectFrame(){
1486 include = [1,-1] * (epp2i[0] + 4);
1489 cube(1000, center=true);
1490 translate([0,0, -100])
1491 linear_extrude(height=200)
1492 rectfromto(include, inside_br - include);
1496 translate([ 0, -phone[1] * i/3, 0 ])
1497 cube(center=true, [1000, 4, 100]);
1501 module TestSelectLidFrame(){
1504 translate([led_pos[0], -led_pos[1], -50])
1505 cylinder(r= nla_r2+3, h=100);
1508 module TestFrameCase(){ ////toplevel
1514 TestSelectOrdinaryRearApertures();
1519 module TestSelectTopApertures(){
1520 translate([-100, -35, -100])
1521 cube([400, 100, 200]);
1522 LidAdhocMultiprintFrame(0);
1523 LidAdhocMultiprintFrame(1);
1526 module TestTopApertures(){ ////toplevel
1530 TestSelectTopApertures();
1534 module TestLidTopAperturesPrint(){ ////toplevel
1535 rotate([0,180,0]) intersection(){
1537 TestSelectLidFrame();
1538 TestSelectTopApertures();
1542 module TestLidWindowTopAperturesPrint(){ ////toplevel
1543 rotate([0,180,0]) intersection(){
1545 TestSelectTopApertures();
1549 module TestFrameLidPrint(){ ////toplevel
1550 rotate([0,180,0]) intersection(){
1552 TestSelectLidFrame();
1556 module ButtonPlanForDemo(z, deep, cut){
1558 ButtonPlan(8, deep, cut);
1561 module HingeScrews(){
1562 Flip_rhs() Flip_bot(1){
1563 for (c= [ hppT, hppB ])
1568 translate([0,0,-.2])
1569 cylinder( r= hingescrew_shaft_dia/2,
1570 h = hingescrew_shaft_len+0.2 );
1572 translate([0,0,+.1])
1573 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1578 module DemoPropAngleSelect(c){
1579 color(c) difference(){
1580 union(){ children(); }
1581 translate([ prop_x_pos, -400, -200 ])
1582 cube([ 400,800,400 ]);
1586 module DemoPropAngle(ang){
1587 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1588 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1596 DemoPropAngleSelect("red") Case();
1599 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1600 PropProfileAssignments(ang) {
1602 rotate([-$prp_theta, 0, 0])
1603 translate([0, $prpp1[0], -$prpp1[1]])
1609 translate([0,0, -hp_k*2])
1610 DemoPropAngleSelect("blue")
1614 module DemoPropAngles(){ ////toplevel
1615 for (i=[0 : len(prop_angles)-1])
1616 translate(i * [0, -100, 100])
1617 DemoPropAngle(prop_angles[i]);
1620 module DemoHingeAngle(ang1,ang2){
1621 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1622 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1633 color("blue") intersection(){
1636 translate([bppJ[0], -400, -200])
1638 cube([400, 800, 400]);
1639 translate([10, -400, -200])
1640 cube([10, 800, 400]);
1645 module DemoHingeAngles(){ ////toplevel
1646 angles = [ 0, 4, 8, 12 ];
1647 echo("angles",angles);
1648 for (i=[0 : len(angles)-1]) {
1649 translate(i * [0, 0, 30]) {
1650 DemoHingeAngle(0,angles[i]);
1651 translate([0, 200, 0])
1652 DemoHingeAngle(angles[i],0);
1657 module DemoSelectAdhocLeftRight(right=0) {
1658 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1659 mirror([1-right, 0,0])
1660 cube([400, 800, 200]);
1663 module DemoLeft(){ ////toplevel
1664 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1665 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1668 module DemoFrame(){ ////toplevel
1669 color("red") render() TestFrameCase();
1670 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1671 color("black") render() HingeScrews();
1672 %render() HingeLever();
1675 module DemoLanyardCutout(){ ////toplevel
1679 module DemoHingedFrame(){ ///toplevel
1680 color("red") render() TestFrameCase();
1681 translate([0,0, -2*hp_k])
1682 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1685 color("orange") render() HingeLever();
1686 color("black") render() HingeScrews();
1690 module DemoHinge(){ ////toplevel
1691 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1693 translate([0,0, -hp_k*3])
1698 module DemoProfiles(){ ////toplevel
1702 translate([0,0,-1]) color("black") KeeperProfile(1);
1705 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1706 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1707 translate([0, ly_q_z]){
1708 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1709 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1713 translate([0,0,-5]) color("white") translate(epp2i)
1715 rectfromto([-15, 0],
1716 [+15, -max_case_bottom_edge_thickness]);
1719 LanyardMainChannelProfile();
1720 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1721 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1728 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1730 color("blue") ButtonCoverProfile();
1732 rectfromto(bppQ, demopoint_QR);
1733 rectfromto(bppR, demopoint_QR);
1737 translate([-20,0]) {
1738 color("black") ButtonPlanForDemo(-2, 0,1);
1739 color("red" ) ButtonPlanForDemo(-4, 1,1);
1740 color("blue") ButtonPlanForDemo(-6, 1,0);
1743 translate([0, -30]) {
1746 color("blue") HingeLidProfile();
1747 color("red") HingeBaseProfile();
1748 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1752 translate([-30, -60 + 30*f]) {
1753 translate([0,0,-4]) EdgeProfile();
1754 %translate([0,0,-10]) HingeBaseProfile();
1755 translate([0,-2] * f * hp_k) {
1756 translate([0,0,-4]) LidEdgeProfile();
1757 %translate([0,0,-10]) %HingeLidProfile();
1759 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1760 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1761 translate([0,0,0]) color("red") difference(){
1762 HingeLeverOuterProfile();
1763 HingeLeverInnerProfile();
1765 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1770 translate([20,-30]) {
1773 //translate([0,0,1]) ThumbRecessCutProfile();
1774 translate([0,0,+1]) color("red")
1775 difference(){ EdgeProfile(); ThumbRecessCutProfile(); }
1778 translate([40,-30]) {
1782 PropProfile(10, 1, 0);
1787 translate([60,-30]) {
1788 PropAggregateProfile();