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 = [ 75.86, 162.0 ];
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 = 0;
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
145 phone_cnr_rad = 7.0; // actuall 8.mumble, but smaller is fine
146 phone_rim_depth = 0.01; // includes allowance for a screen protector
148 button_cutout_depth = 9;
150 phone_edge_thick = 11.25;
152 // xxx this is all wrong
153 camera_pos_tl = [ 6.450, 12.750 ]; // measured from tl corner
154 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
156 // this is disabled, FP4 doesn't have one
157 jack_pos = [ 13.83, 8.485 ];
158 jack_dia = 10.64 + .5; // some jack I had lying around
160 // this led stuff, is irrelevant, we have disabled it as it doesn't have one
161 led_pos = [ 13.98, 10.00 ];
163 led_window_ledge = 0.75; // each side
165 noisecancelmic_pos = [ 15.08, 4.35 ]; // from rhs, from top edge
166 noisecancelmic_dia = 4.00;
168 lhshole_pos = [ phone[1]/2, 4.35 ];
170 // fingerpushhole_dias = []; xxx what was this
171 fingerpushhole_dias = [ 15, 18 ];
173 lanyard_half_dia = 1.15;
174 lanyard_entry_rel_breadth = 2;
175 lanyard_channel_len = 8;
176 rearspeaker_pos_bl = [ 12.64, 18.72 ];
177 rearspeaker_size = [ 3.76, 7.36 ];
179 bottomspeaker_size = [ 11.35, 1.40 ] + [1,1] * 1.0;
180 bottomspeaker_pos = [ 19.45, 4.82 ];
182 microusb_above = 1.64 - 0.25;
183 microusb_below = 2.42;
184 microusb_width = 12.16 + 2.0 + 1.25;
186 case_th_bottom = 2.5;
191 lid_screen_gap_extra = .66;
193 case_struts_count = 6;
194 case_struts_solid_below = 1.00;
195 case_struts_solid_above = 0.75;
196 case_struts_width = 0.10;
200 keeper_inner_width = 2.75;
201 keeper_inner_height = 2.75;
202 keeper_slant_slope = 2; // larger means steeper
204 keeper_gap_z_top = 0.25;
205 keeper_gap_z_bot = 0.75;
207 keeper_gap_x_holes = 0.75;
209 keeper_side = 0; // 0 = lhs; 1 = rhs
216 lid_edgepart_width = 5.0;
217 lid_buttoncover_thick = 1.3;
218 lid_buttoncover_reinf = 0.65;
221 foldover_lever_gap = 0.50;
223 // xxx replace hinge screw with nail plan
225 // properties of the hinge fasteners
226 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
227 hingescrew_shaft_len = 12;
228 hingescrew_fasteners_extra_thick = 0.40;
229 // ^ amount of thread protruding if everything was completely nominal
230 // and we are using two nuts
231 hingescrew_nut_access_dia = 4.72 + 0.50;
232 // ^ washer is 4.72 dia
233 // also, want to get pliers or tiny spanner in to do up locknut
234 hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
235 hingescrew_nut_thick = 1.93;
236 hingescrew_head_th = 1.38 + 0.75;
237 hingescrew_head_dia = 3.92;
239 hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
241 lever_cover_th = 0.75;
243 hingemount_wd = 4.8725;
248 button_l_fudge = 4.4;
249 buttonishleg_default_l_is_fudge = 10;
251 hinge_base_slope = 1.5; // bigger is steeper
253 strut_min_at_end = 1.5;
256 hinge_x_postscrew_gap = 0.75;
257 hinge_x_arms_gap = 0.35;
258 hinge_r_arms_gap = 0.55;
260 // xxx there isn't one of these, speaker is by hinge
261 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
263 thumbrecess_depth = 1.3;
264 thumbrecess_width = 16.5;
265 thumbrecess_topcurve_r = 5.0;
267 prop_recess_under = 0.50;
268 prop_recess_slop = 0.200; // each side
273 prop_side_gap = 0.75; // each side
274 prop_lidrecess_behind = 0.75;
275 prop_caserecess_behind = 0.75;
276 prop_caserecess_taper = 0.45; // one side only
278 prop_prong_heel_slope = 0.5;
280 lid_fold_clearance_antislop = 0.5;
282 $button_leg_only = false;
283 $suppress_forward_holes = false;
285 // ---------- calculated ----------
287 phone_total_thick = phone_edge_thick;
289 phone_width = (phone + bumper*2)[0];
290 phone_height = (phone + bumper*2)[1];
292 inside_br = [phone_width, -phone_height];
294 prop_prong_h = prop_main_th;
296 //echo(camera_pos_tl + bumper,
297 // camera_pos_br + bumper);
299 // ----- could be changed -----
300 lid_buttoncover_gap = lid_gap_x;
301 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
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; // conflated for FP4
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);
431 // thumb recess (used to be "catch" hence cpp*
433 cppA = epp4 + [thumbrecess_depth, 0];
434 cppB = [ cppA[0], epp1[1] ];
438 ly_r = lanyard_half_dia / 2;
442 ly_o = epp2i + 3 * ly_r * [0,1];
444 max_case_bottom_edge_thickness =
447 ly_q_z = -(ly_rc + ly_r);
448 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
450 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
452 // prop recess in case
454 prop_x_pos = phone_width/2;
456 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
458 prc_r1 = prop_end_dia/2;
459 prc_r3 = prc_r1 + prop_recess_slop;
461 prcp2 = [ epp4[0] + prop_buildout_less,
464 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
466 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
467 epp2i[1] - prc_r3 - prop_recess_under];
469 // prop recess in lid
471 prl_r10 = prop_end_dia/2;
472 prl_r10o = prl_r10 + prop_recess_slop;
474 prlp10 = lpp10 + [1,1] * prl_r10o
475 + [1,0] * prop_lidrecess_behind
476 + [0,1] * prop_recess_under;
481 $prpp11 = [0, prop_taper_len];
485 // ---------- modules ----------
487 module AdhocMultiprintFrame(phase, z0, zs) {
488 // from z0 to z0 + zs*layer
489 extra = phase * (initial_layer_width + multicolour_gap) + 5;
490 xextra = extra + -epp4[0];
491 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
492 yextra = extra + -epp4[0];
493 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
494 p0 = [ xrange[0], yrange[0] ];
495 p1 = [ xrange[1], yrange[1] ];
498 mirror([0,0, zs<0 ? 1 : 0])
499 linear_extrude(height= initial_layer_thick)
501 rectfromto(p0 - [1,1] * initial_layer_width,
502 p1 + [1,1] * initial_layer_width);
507 module KeeperProfile(slant=0){
508 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
509 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
512 module EdgeProfile(){
515 translate(epp3) square(case_th_bottom*2, center=true);
516 circleat(epp2o, r=case_th_bottom);
517 circleat(epp1, r=case_th_side);
518 rectfromto(epp0, epp4);
520 polygon([ epp5 + [0,10],
526 module LanyardLanyardProfile(entry=false){
528 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
529 translate(xs * 0.5 * lanyard_half_dia * [1,0])
530 circle(r= lanyard_half_dia/2);
534 module LanyardCurveChannelProfile(){
535 translate([0, -ly_r])
536 LanyardLanyardProfile();
539 module LanyardEntryChannelProfile(){
540 LanyardLanyardProfile(true);
543 module LanyardMainChannelProfile(){
544 LanyardCurveChannelProfile();
546 square(center=true, ly_r * [6, 2]);
548 translate(ly_r * [3 * xs, -1])
553 module LanyardEntryOuterProfile(){
554 circleat([ly_re + ly_r, 0], ly_re);
557 module LanyardEntry(){
563 translate([d_x, 0, q_z]) {
566 rotate_extrude(convexity=10)
569 LanyardCurveChannelProfile();
577 linear_extrude(height=20)
579 LanyardEntryChannelProfile();
581 translate([0, ly_r*2, 0])
583 linear_extrude(height = ly_r*4){
585 rectfromto([d_x, q_z], [ly_r, 0]);
586 circleat([d_x, q_z], ly_rc);
590 translate([0,0,q_z]){
593 translate([0, oec_y, 0]){
595 translate(ly_re * [-1,0,-2])
596 cube(ly_re * [2,1,2]);
597 rotate_extrude(convexity=10)
598 LanyardEntryOuterProfile();
603 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
604 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
609 linear_extrude(height=20)
610 LanyardEntryOuterProfile();
615 module LanyardCutout(l){
617 linear_extrude(height=l)
619 LanyardMainChannelProfile();
622 translate(ee * l * [-1,0])
628 module LidEdgeProfile(){
639 circleat(lpp12, r=lp_r12);
640 rectfromto( lpp12 + [-10, 0],
641 lpp12 + [+10, +10] );
645 module LidEdgeFoldClearanceProfile(){
646 translate([-lid_fold_clearance_antislop, 0])
655 module ButtonCoverProfile(){
657 polygon(concat([ bppM, bppP, bppO, bppJ ],
658 (enable_support && !$button_suppress_over_keeper
659 ? [ bppU, bppV, bppW ] : []),
668 module ButtonPlan(l, deep, cut){
670 (cut ? 0 : lid_buttoncover_gap);
673 (deep ? lid_buttoncover_overlap : 0);
675 C = [0,0]; // by definition
679 B0 = C + [0,-1] * button_cutout_depth;
680 B1 = B0 + [0,1] * epsilon;
682 r0 = 0.5 * (T[1] - B0[1]);
683 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
684 H = A + [0,-1] * delta;
690 E1 = E0 + [1,0] * epsilon;
692 I0 = [ E0[0], H[1] ];
693 I1 = [ E1[0], H[1] ];
696 for (m=[0,1]) mirror([m,0])
697 circleat(H, r0 - epsilon);
699 for (m=[0,1]) mirror([m,0]) {
709 circleat(D, r0 + epsilon);
714 module ButtonCoverReinf(){ ////toplevel
717 linear_extrude(height=0.01)
719 ButtonCoverProfile();
720 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
723 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
724 circle(r= lid_buttoncover_reinf);
725 translate([-20,0]) square(40, center=true);
730 module ThumbRecessCutProfile(){
732 polygon([ cppA + [-10,0],
736 circleat(epp1, r=case_th_side);
740 module Flip_rhs(yn=[0,1]) {
742 translate([phone_width/2, 0, 0])
743 mirror([$rhsflip,0,0])
744 translate([-phone_width/2, 0, 0])
749 module Flip_bot(yn=[0,1]) {
751 translate([0, -phone_height/2, 0])
752 mirror([0, $botflip, 0])
753 translate([0, phone_height/2, 0])
758 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
761 translate([0, -phone_cnr_rad, 0])
763 linear_extrude(height = phone_height - phone_cnr_rad*2)
767 Flip_rhs() Flip_bot() {
768 translate([+1,-1] * phone_cnr_rad)
773 translate([-1,0] * phone_cnr_rad)
775 rectfromto([0,-20],[10,20]);
777 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
783 translate([ phone_width - phone_cnr_rad, 0,0 ])
785 linear_extrude(height = phone_width - phone_cnr_rad*2)
789 translate([0,0, fill_zstart])
790 mirror([0,0, fill_downwards])
791 linear_extrude(height = fill_th)
792 rectfromto([+1,-1] * phone_cnr_rad,
793 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
796 module CaseAperture(pos, dia, $fn, topbottom=0) {
798 translate([ bumper[0],
801 rotate([0,0, 90*topbottom])
802 translate([ pos[0] * (topbottom>0 ? -1 : +1), 0, -pos[1] ])
803 rotate([-90, theta, 0])
804 cylinder(r = dia/2 / cos(theta),
808 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
810 // +1 measured from top of actual phone to top of button
811 // -1 measured from bottom of actual phone to bottom of button
812 // 0 y is centre of button in coordinate system
814 $button_suppress_over_keeper= suppress_over_keeper;
815 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
816 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
819 translate([0, eff_y, 0])
823 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
824 $button_leg_only = true;
825 SideButton(y, y_ref_sign, l) children();
829 Flip_rhs(1) SideButton(30.320, +1, 22.960 ) children(); // volume
830 Flip_rhs(1) SideButton(64.220, +1, 14.500 ) children(); // power
831 Flip_rhs(1) LidButtonishLeg(14, -1) children();
832 Flip_rhs(0) LidButtonishLeg(21, -1) children();
833 Flip_rhs(0) LidButtonishLeg(14, +1) children();
834 // xxx need hole for whatever that hole is on lhs
837 module Struts(x_start, z_min, th){
838 // if th is negative, starts at z_min and works towards -ve z
839 // and object should then be printed other way up
840 for (i= [1 : 1 : case_struts_count]) {
844 mirror([0,0, th<0 ? 1 : 0])
846 -phone_height * i / (case_struts_count+1),
847 case_struts_solid_below])
848 linear_extrude(height= abs(th)
849 -(case_struts_solid_below+case_struts_solid_above))
850 rectfromto([ x_start, -0.5 * case_struts_width ],
851 [ phone_width - x_start, +0.5 * case_struts_width ]);
855 module OrdinaryRearAperture(rhs,bot, pos){
856 Flip_rhs(rhs) Flip_bot(bot)
859 translate(pos + bumper)
863 module MicroUSBEtc(){
867 linextr(-epp2i[0], 60)
868 translate([0.5 * phone_width, 0, 0])
869 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
870 [+microusb_width/2, epp0[1] + -microusb_above]);
874 module OrdinaryBottomEdgeApertures(){
875 Flip_bot(1) Flip_rhs(1) {
876 linextr_y_xz(-epp2i[0], 60)
879 translate([ -bottomspeaker_pos[0], -bottomspeaker_pos[1] ] +
880 [ 0.5 * x * bottomspeaker_size[0] - bottomspeaker_size[1],
883 circle(r = bottomspeaker_size[1], $fn = 8);
888 module OrdinaryRearApertures(){
890 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
891 rectfromto(-rearspeaker_gap,
892 rearspeaker_size + rearspeaker_gap);
894 // finger hole to remove phone
895 if (len(fingerpushhole_dias))
896 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
898 scale(fingerpushhole_dias)
902 module RearCameraAperture(){
905 linear_extrude(height = 20)
908 rectfromto(camera_pos_tl, camera_pos_br);
911 module HingeLidProfile(){
913 circleat(hppT, hp_r1);
914 circleat(lpp12, lp_r12);
922 module HingeBaseProfile(){
925 circleat(hppB, hp_r1);
926 circleat(hppE, hp_r1);
927 circleat(epp2o, case_th_bottom);
928 circleat(hppB + [10,0], hp_r1);
930 polygon([epp5, epp1, epp3, bppL]);
934 module HingeLeverOuterProfile(){
936 circleat(hppT, hp_r2);
937 circleat(hppB, hp_r2);
941 module HingeLeverInnerProfile(){
943 c = s > 0 ? hppT : hppB;
945 mirror([0,0, s>0 ? 1 : 0])
946 rotate(s<0 ? -40 : 0)
955 module HingeLeverNutProfile(){
956 for (c= [hppB, hppT]) {
958 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
962 module Flip_hinge(doflip=1){
963 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
964 translate(hinge_origin)
965 rotate([doflip*180,0,0])
966 translate(-hinge_origin)
970 module HingePortion(x0,x1){
971 Flip_rhs() Flip_bot(1)
975 linear_extrude(height=x1-x0)
979 module ThumbRecessApply(ztop){
980 width = thumbrecess_width;
981 w = width + thumbrecess_topcurve_r*2 + 1;
982 translate([phone_width/2, 0,0]){
987 translate([0, 50, 0])
989 linear_extrude(height=100){
990 for (m=[0,1]) mirror([m,0,0]) {
992 translate([w/2, ztop - thumbrecess_topcurve_r])
993 circle(thumbrecess_topcurve_r);
994 translate([w/2, -50])
995 square(thumbrecess_topcurve_r*2, center=true);
1004 AroundEdges(epp3[1], case_th_bottom, 1)
1008 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
1010 module PropProfileAssignments(gamma){
1011 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
1013 p = phone_height + prlp10[0] - hppB[0];
1016 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
1018 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
1019 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
1021 $prp_theta = 90 - $prp_alpha;
1022 beta = 180 - $prp_alpha - gamma;
1025 //echo("abc", a,b,c);
1027 v1 = [ [ cos(psi), -sin(psi) ], // x
1028 [ sin(psi), cos(psi) ] ]; // y
1030 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1033 $prp_r11 = prop_main_th/2;
1035 $prpp1 = $prpp7 + [1,0] *
1036 // this is approximate, but will do
1037 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1040 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1041 $prpp12 = $prpp3 + v1[0] *
1042 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1043 $prp_r8 = prop_main_th;
1044 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1046 $prpp5 = [ $prpp12[0] - $prp_r5,
1047 $prpp3[1] - prop_prong_h + $prp_r5 ];
1048 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1049 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1050 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1051 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1056 module PropProfile(gamma, cut=0, rot=0){
1057 PropProfileAssignments(gamma){
1059 //#circleat($prpp3,1);
1060 //#circleat($prpp12,1);
1067 polygon([[-20,-0], [20,20], [0,0]]);
1069 rectfromto($prpp6, $prpp9);
1070 translate($prpp5) intersection(){
1072 polygon([[-10,-10], [0,0], [10,0]]);
1074 rectfromto($prpp12 + [0,-0.1], $prpp3);
1077 circleat($prpp1, $prp_r1);
1078 rectfromto($prpp12 + [0,-0.1], $prpp3);
1082 rotate([0,0, rot*-$prp_theta]){
1084 extra = cut ? prop_recess_slop : 0;
1085 rectfromto($prpp6, $prpp9);
1086 circleat($prpp11, $prp_r11 + extra);
1087 circleat($prpp10, $prp_r10 + extra);
1093 module PropAggregateProfile(){
1094 for (angle = prop_angles)
1095 PropProfile(angle, 0,0);
1098 module Prop(){ ////toplevel
1099 hw = prop_main_width/2;
1101 PropAggregateProfile();
1104 module Case(){ ////toplevel
1109 // ledge (fixed keeper)
1110 Flip_rhs(1-keeper_side) intersection(){
1112 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1115 // outline of the whole case, to stop it protruding
1116 translate([0,0, -25])
1117 linear_extrude(height = 50)
1120 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1124 HingePortion(hex20, hex21) HingeBaseProfile();
1126 // buildout for prop recess
1127 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1128 linextr(case_bottom_z, epp2i[1])
1131 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1133 r = epp2o[0] - prcp2[0]);
1138 Flip_rhs(keeper_side)
1139 translate([0, -phone_cnr_rad, 0])
1141 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1144 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1145 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1149 RearCameraAperture();
1151 // struts (invisible, because they're buried in the case)
1152 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1157 if (!($button_leg_only && enable_support))
1159 translate([0,0,-10])
1160 linear_extrude(height= 20)
1161 ButtonPlan($button_l, 0,1);
1162 if ($button_leg_only)
1164 translate([phone_width/2, -400, kppe[1]])
1165 mirror([1-abs($rhsflip - keeper_side),0,0])
1166 cube([400, 800, 50]);
1167 if (enable_support && !$button_suppress_over_keeper)
1169 translate([-400, -400, kppd[1]])
1171 cube([800,800,100]);
1173 translate([0,0, -bppR[0]])
1174 linear_extrude(height= 20)
1175 ButtonPlan($button_l, 1,1);
1180 // apertures along top edge
1181 if (!$suppress_forward_holes) {
1182 // CaseAperture(jack_pos, jack_dia, 8);
1184 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1185 CaseAperture(lhshole_pos, noisecancelmic_dia, 8, 1);
1188 OrdinaryBottomEdgeApertures();
1190 OrdinaryRearApertures();
1194 // gaps for the lid's hinge arms
1195 HingePortion(hex20 - hinge_x_arms_gap,
1196 hex21 + hinge_x_arms_gap)
1199 circle(r= hinge_r_arms_gap, $fn= 8);
1202 // screw holes in the hinge arms
1206 ThumbRecessApply(epp4[1])
1207 ThumbRecessCutProfile();
1211 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1212 rotate([0, ly_theta, 0])
1214 LanyardCutout(lanyard_channel_len);
1218 translate([prop_x_pos,0,0])
1221 linextr(-prop_recess_hw, +prop_recess_hw)
1223 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1224 circleat(prcp1 + 20*d,
1230 module LidAdhocMultiprintFrame(phase){
1231 if (led_window_style >= 3) {
1232 AdhocMultiprintFrame(phase, lpp13[1], -1);
1236 module LidAroundEdges(){
1237 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1241 module Lid(){ ////toplevel
1242 skew_centre = [0, lpp11[0], lpp11[1]];
1249 translate(skew_centre)
1250 multmatrix([[ 1, 0, 0, 0 ],
1251 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1254 translate(-skew_centre)
1256 LidEdgeFoldClearanceProfile();
1263 translate([0,0,-10])
1264 linear_extrude(height= 20)
1265 ButtonPlan($button_l, 1,0);
1268 translate([0,0,-100])
1269 linear_extrude(height= 200)
1270 ButtonCoverProfile();
1272 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1273 - lid_buttoncover_reinf))
1281 HingePortion(hex20, hex21) {
1286 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1288 // screw holes in the hinge arms
1292 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1295 linextr(-prop_recess_hw, +prop_recess_hw)
1297 for (pa = prop_angles)
1298 PropProfile(pa, 1,1);
1300 // notification led aperture
1301 if (led_window_style)
1302 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1303 translate([0,0,-10])
1304 cylinder(r=nla_r0, h=20);
1305 if (led_window_style >= 2)
1306 translate([0,0, -nla_t])
1307 cylinder(r=nla_r2, height=20);
1312 LidAdhocMultiprintFrame(1);
1315 module HingeLever(){ ////toplevel
1317 // outer body, positive
1318 HingePortion(hex22, hex22 + phone_width/2)
1319 HingeLeverOuterProfile();
1321 // space for the screws
1322 HingePortion(hex26, hex24)
1323 HingeLeverInnerProfile();
1325 // recesses for the nuts
1326 HingePortion(hex23, hex26+1)
1327 HingeLeverNutProfile();
1329 // bores for the screws
1332 // space for the charging cable
1334 Flip_hinge() MicroUSBEtc();
1338 module LidWindow(){ ////toplevel
1339 translate([led_pos[0], -led_pos[1], lpp13[1]])
1341 cylinder(r= nla_r1, h=nla_t);
1342 LidAdhocMultiprintFrame(0);
1345 module LidWindowPrint(){ ////toplevel
1350 module DemoLidWindowSelect(){
1351 translate([led_pos[0], led_pos[1], -100]) {
1352 translate([0, -30, 0]) cube([400, 400, 200]);
1356 module DemoLidWindow(){ ////toplevel
1359 translate([0,40,0]){
1360 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1361 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1365 module HingeLeverPrint(){ ////toplevel
1367 translate([-phone_width/2, phone_height, 0])
1371 module TestSelectLength(){
1372 translate([-30, -200, -20])
1373 cube([30 + 15, 250, 40]);
1376 module TestLength(){ ////toplevel
1383 module TestLengthRight(){ ////toplevel
1391 module TestSelectWidth(){
1392 translate([-30, -(phone_height - 25), -20])
1394 cube([200, 50, 40]);
1397 module TestWidth(){ ////toplevel
1404 module TestLidWidthPrint(){ ////toplevel
1405 rotate([0,180.0]) intersection(){
1411 module TestSelectRearAperture(){
1414 translate([20, 0,0])
1415 cube([42, 2, 1], center=true);
1419 module TestSelectCamera(){
1421 TestSelectRearAperture()
1422 RearCameraAperture();
1423 cube([0.1, 50, 0.1]);
1427 module TestSelectOrdinaryRearApertures(){
1428 TestSelectRearAperture()
1429 OrdinaryRearApertures();
1432 module TestCamera(){ ////toplevel
1439 module TestLidByCamera(){ ////toplevel
1446 module TestLidByCameraPrint(){ ////toplevel
1447 rotate([180,0,0]) TestLidByCamera();
1450 module DemoByCamera(){ ////toplevel
1451 color("blue") TestLidByCamera();
1452 color("red") TestCamera();
1455 module OneKeeper(){ ////toplevel
1456 translate([0, -phone_cnr_rad, 0])
1458 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1462 module OneKeeperPrint(){ ////toplevel
1467 module LidPrint(){ ////toplevel
1472 module TestSelectFrame(){
1473 include = [1,-1] * (epp2i[0] + 4);
1476 cube(1000, center=true);
1477 translate([0,0, -100])
1478 linear_extrude(height=200)
1479 rectfromto(include, inside_br - include);
1483 module TestSelectLidFrame(){
1485 translate([led_pos[0], -led_pos[1], -50])
1486 cylinder(r= nla_r2+3, h=100);
1489 module TestFrameCase(){ ////toplevel
1495 TestSelectOrdinaryRearApertures();
1500 module TestSelectTopApertures(){
1501 translate([-100, -35, -100])
1502 cube([400, 100, 200]);
1503 LidAdhocMultiprintFrame(0);
1504 LidAdhocMultiprintFrame(1);
1507 module TestTopApertures(){ ////toplevel
1511 TestSelectTopApertures();
1515 module TestLidTopAperturesPrint(){ ////toplevel
1516 rotate([0,180,0]) intersection(){
1518 TestSelectLidFrame();
1519 TestSelectTopApertures();
1523 module TestLidWindowTopAperturesPrint(){ ////toplevel
1524 rotate([0,180,0]) intersection(){
1526 TestSelectTopApertures();
1530 module TestFrameLidPrint(){ ////toplevel
1531 rotate([0,180,0]) intersection(){
1533 TestSelectLidFrame();
1537 module ButtonPlanForDemo(z, deep, cut){
1539 ButtonPlan(8, deep, cut);
1542 module HingeScrews(){
1543 Flip_rhs() Flip_bot(1){
1544 for (c= [ hppT, hppB ])
1549 translate([0,0,-.2])
1550 cylinder( r= hingescrew_shaft_dia/2,
1551 h = hingescrew_shaft_len+0.2 );
1553 translate([0,0,+.1])
1554 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1559 module DemoPropAngleSelect(c){
1560 color(c) difference(){
1561 union(){ children(); }
1562 translate([ prop_x_pos, -400, -200 ])
1563 cube([ 400,800,400 ]);
1567 module DemoPropAngle(ang){
1568 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1569 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1577 DemoPropAngleSelect("red") Case();
1580 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1581 PropProfileAssignments(ang) {
1583 rotate([-$prp_theta, 0, 0])
1584 translate([0, $prpp1[0], -$prpp1[1]])
1590 translate([0,0, -hp_k*2])
1591 DemoPropAngleSelect("blue")
1595 module DemoPropAngles(){ ////toplevel
1596 for (i=[0 : len(prop_angles)-1])
1597 translate(i * [0, -100, 100])
1598 DemoPropAngle(prop_angles[i]);
1601 module DemoHingeAngle(ang1,ang2){
1602 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1603 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1614 color("blue") intersection(){
1617 translate([bppJ[0], -400, -200])
1619 cube([400, 800, 400]);
1620 translate([10, -400, -200])
1621 cube([10, 800, 400]);
1626 module DemoHingeAngles(){ ////toplevel
1627 angles = [ 0, 4, 8, 12 ];
1628 echo("angles",angles);
1629 for (i=[0 : len(angles)-1]) {
1630 translate(i * [0, 0, 30]) {
1631 DemoHingeAngle(0,angles[i]);
1632 translate([0, 200, 0])
1633 DemoHingeAngle(angles[i],0);
1638 module DemoSelectAdhocLeftRight(right=0) {
1639 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1640 mirror([1-right, 0,0])
1641 cube([400, 800, 200]);
1644 module DemoLeft(){ ////toplevel
1645 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1646 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1649 module DemoFrame(){ ////toplevel
1650 color("red") render() TestFrameCase();
1651 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1652 color("black") render() HingeScrews();
1653 %render() HingeLever();
1656 module DemoLanyardCutout(){ ////toplevel
1660 module DemoHingedFrame(){ ///toplevel
1661 color("red") render() TestFrameCase();
1662 translate([0,0, -2*hp_k])
1663 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1666 color("orange") render() HingeLever();
1667 color("black") render() HingeScrews();
1671 module DemoHinge(){ ////toplevel
1672 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1674 translate([0,0, -hp_k*3])
1679 module DemoProfiles(){ ////toplevel
1683 translate([0,0,-1]) color("black") KeeperProfile(1);
1686 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1687 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1688 translate([0, ly_q_z]){
1689 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1690 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1694 translate([0,0,-5]) color("white") translate(epp2i)
1696 rectfromto([-15, 0],
1697 [+15, -max_case_bottom_edge_thickness]);
1700 LanyardMainChannelProfile();
1701 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1702 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1709 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1711 color("blue") ButtonCoverProfile();
1713 rectfromto(bppQ, demopoint_QR);
1714 rectfromto(bppR, demopoint_QR);
1718 translate([-20,0]) {
1719 color("black") ButtonPlanForDemo(-2, 0,1);
1720 color("red" ) ButtonPlanForDemo(-4, 1,1);
1721 color("blue") ButtonPlanForDemo(-6, 1,0);
1724 translate([0, -30]) {
1727 color("blue") HingeLidProfile();
1728 color("red") HingeBaseProfile();
1729 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1733 translate([-30, -60 + 30*f]) {
1734 translate([0,0,-4]) EdgeProfile();
1735 %translate([0,0,-10]) HingeBaseProfile();
1736 translate([0,-2] * f * hp_k) {
1737 translate([0,0,-4]) LidEdgeProfile();
1738 %translate([0,0,-10]) %HingeLidProfile();
1740 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1741 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1742 translate([0,0,0]) color("red") difference(){
1743 HingeLeverOuterProfile();
1744 HingeLeverInnerProfile();
1746 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1751 translate([20,-30]) {
1754 //translate([0,0,1]) ThumbRecessCutProfile();
1755 translate([0,0,+1]) color("red")
1756 difference(){ EdgeProfile(); ThumbRecessCutProfile(); }
1759 translate([40,-30]) {
1763 PropProfile(10, 1, 0);
1768 translate([60,-30]) {
1769 PropAggregateProfile();