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, 7.37 /* xxx? */ ]; // from rhs
166 noisecancelmic_dia = 4.00;
168 // fingerpushhole_dias = []; xxx what was this
169 fingerpushhole_dias = [ 15, 18 ];
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 = 1.64 - 0.25;
178 microusb_below = 2.42;
179 microusb_width = 12.16 + 2.0 + 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 = 0.65;
216 foldover_lever_gap = 0.50;
218 // xxx replace hinge screw with nail plan
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 // xxx there isn't one of these, speaker is by hinge
256 rearspeaker_gap = [ 2.0, 2.0 ]; // each side
258 thumbrecess_depth = 1.3;
259 thumbrecess_width = 16.5;
260 thumbrecess_topcurve_r = 5.0;
262 prop_recess_under = 0.50;
263 prop_recess_slop = 0.200; // each side
268 prop_side_gap = 0.75; // each side
269 prop_lidrecess_behind = 0.75;
270 prop_caserecess_behind = 0.75;
271 prop_caserecess_taper = 0.45; // one side only
273 prop_prong_heel_slope = 0.5;
275 lid_fold_clearance_antislop = 0.5;
277 $button_leg_only = false;
278 $suppress_forward_holes = false;
280 // ---------- calculated ----------
282 phone_total_thick = phone_edge_thick;
284 phone_width = (phone + bumper*2)[0];
285 phone_height = (phone + bumper*2)[1];
287 inside_br = [phone_width, -phone_height];
289 prop_prong_h = prop_main_th;
291 //echo(camera_pos_tl + bumper,
292 // camera_pos_br + bumper);
294 // ----- could be changed -----
295 lid_buttoncover_gap = lid_gap_x;
296 lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
298 //prop_lidrecess_depth = case_th_lid - prop_recess_under;
300 //prop_nose_len = case_th_lid - prop_recess_under;
301 //prop_recess_slope = tan(prop_max_angle); // bigger means steeper
302 //prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
305 //lid_lip_overlap_width xxx bad name = ;
306 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
309 epp1 = [0, -phone_edge_thick];
310 epp2i = epp1; // conflated for FP4
312 epp3 = epp2i + [10, 0];
313 epp5 = epp0 + [0,1] * (keeper_th_z + keeper_gap_z_top + case_lip);
314 epp4 = epp5 + [-1,0] * case_th_side;
317 kppd = kppe + [1,0] * keeper_inner_width;
318 kppc = kppd + [0,1] * keeper_th_z;
319 kppb = [ kppe[0] - keeper_th_x, kppc[1] ];
320 kppf = kppe - [0,1] * keeper_inner_height;
321 kppa = [ kppb[0], kppf[1] ];
323 lpp10 = [ epp5[0] + lid_gap_x, kppc[1] + lid_gap_z ];
324 lpp11 = [ lpp10[0], epp5[1] + lid_gap_z ];
326 lpp14 = lpp10 + [1,0] * max(keeper_inner_width, lid_edgepart_width);
327 // exact x posn not very important; must extend past end of keeper
330 epp0[1] - phone_rim_depth + 1/2.5 * case_th_lid
331 + lid_screen_gap_extra ];
332 // ^ beam theory says to maximise force before contact,
333 // the gap below the `beam' (the lid) must be 1/3
334 // the thickness (ie the lid thickness) if the beam
335 // is solid, or 1/2 if it has a top and bottom only.
336 // ours is mostly solid.
338 lp_r12 = max(case_th_lid - (lpp11[1] - lpp15[1]),
341 lpp12 = [ epp4[0] + lp_r12, lpp11[1] ];
342 lpp13 = [ lpp12[0], lpp12[1] + lp_r12 ];
344 case_bottom_z = epp2o[1] - case_th_bottom;
348 bppN = [ bppM[0] + lid_buttoncover_thick, bppM[1] ];
349 bppR = [ bppN[0] + lid_buttoncover_gap, -button_cutout_depth ];
350 bppS = [ epp1[0], bppR[1] ];
351 bppQ = [ bppM[0], bppR[1] - lid_buttoncover_overlap ];
352 bppP = bppQ + [0,1] * lid_buttoncover_gap;
353 bppO = [ bppN[0], bppP[1] ];
354 bppL = lpp10 + [5,0];
355 bppK = [ bppL[0], bppN[1] ];
356 bppJ = [ bppN[0], bppL[1] ];
357 bppU = [ bppJ[0], lpp12[1] ];
361 echo("BUTTON COVER TH", bppO[0] - bppP[0]);
363 // notification led aperture
365 nla_r0 = led_aperture/2;
366 nla_r1 = nla_r0 + led_window_ledge;
367 nla_r2 = nla_r1 + multicolour_gap;
369 led_window_style >= 3 ? initial_layer_thick :
370 led_window_style >= 2 ? led_window_ledge : 0;
374 hp_rn = hingescrew_nut_access_dia/2;
375 hp_r2_min = hp_rn + lever_cover_th;
376 hp_rs = hingescrew_shaft_dia/2;
377 hp_r1_min = hp_rs + hingemount_th;
379 hp_r1 = max(hp_r1_min, hp_r2_min);
383 hppS = epp2o + [0,-1] * case_th_bottom;
384 hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
386 hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
387 0.5 * (hppU + hppS)[1] ];
388 hppT = [ hppM[0], hppU[1] - hp_r1 ];
389 hppB = hppT + [0,-1] * hp_k;
391 hppE_y = epp2o[1] - case_th_bottom + hp_r1;
392 hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
393 hppE = [ hppE_x, hppE_y ];
395 // hinge elevation x coords
397 hex20 = max(epp2o[0],
399 kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
400 hex21 = hex20 + hingemount_wd;
401 hex22 = hex21 + hinge_x_gap;
402 hex27 = hex20 + hingescrew_shaft_len;
403 hex24 = hex27 + hinge_x_postscrew_gap;
404 hex23 = hex27 - (hingescrew_nut_thick*2
405 + hingescrew_fasteners_extra_thick);
406 hex26 = hex23 + hingescrew_nut_thick * 2/3;
408 echo(hex20, hex21, hex22, hex23, hex24);
409 // 6, 10.8725, 10.9975, 13.74, 18.75
410 module chk(act,exp) {
411 if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
412 else echo("ok", act);
420 lid_fold_clearance_skew =
421 (lpp10[1] - hppB[1]) /
422 (lpp10[0] - hppB[0]);
424 echo("SK",lid_fold_clearance_skew);
426 // thumb recess (used to be "catch" hence cpp*
428 cppA = epp4 + [thumbrecess_depth, 0];
429 cppB = [ cppA[0], epp1[1] ];
433 ly_r = lanyard_half_dia / 2;
437 ly_o = epp2i + 3 * ly_r * [0,1];
439 max_case_bottom_edge_thickness =
442 ly_q_z = -(ly_rc + ly_r);
443 ly_re = max_case_bottom_edge_thickness - (-ly_q_z);
445 ly_oec_y = lanyard_entry_rel_breadth * ly_r;
447 // prop recess in case
449 prop_x_pos = phone_width/2;
451 prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
453 prc_r1 = prop_end_dia/2;
454 prc_r3 = prc_r1 + prop_recess_slop;
456 prcp2 = [ epp4[0] + prop_buildout_less,
459 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
461 prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
462 epp2i[1] - prc_r3 - prop_recess_under];
464 // prop recess in lid
466 prl_r10 = prop_end_dia/2;
467 prl_r10o = prl_r10 + prop_recess_slop;
469 prlp10 = lpp10 + [1,1] * prl_r10o
470 + [1,0] * prop_lidrecess_behind
471 + [0,1] * prop_recess_under;
476 $prpp11 = [0, prop_taper_len];
480 // ---------- modules ----------
482 module AdhocMultiprintFrame(phase, z0, zs) {
483 // from z0 to z0 + zs*layer
484 extra = phase * (initial_layer_width + multicolour_gap) + 5;
485 xextra = extra + -epp4[0];
486 xrange = [ 0, phone_width ] + [-1,+1] * xextra;
487 yextra = extra + -epp4[0];
488 yrange = [ -phone_height + +hppB[0] - hp_r2, 0 ] + [-1,+1] * yextra;
489 p0 = [ xrange[0], yrange[0] ];
490 p1 = [ xrange[1], yrange[1] ];
493 mirror([0,0, zs<0 ? 1 : 0])
494 linear_extrude(height= initial_layer_thick)
496 rectfromto(p0 - [1,1] * initial_layer_width,
497 p1 + [1,1] * initial_layer_width);
502 module KeeperProfile(slant=0){
503 use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
504 polygon([use_e, kppd, kppc, kppb, kppa, kppf]);
507 module EdgeProfile(){
510 translate(epp3) square(case_th_bottom*2, center=true);
511 circleat(epp2o, r=case_th_bottom);
512 circleat(epp1, r=case_th_side);
513 rectfromto(epp0, epp4);
515 polygon([ epp5 + [0,10],
521 module LanyardLanyardProfile(entry=false){
523 for (xs=[-1,+1] * (entry ? lanyard_entry_rel_breadth : 1))
524 translate(xs * 0.5 * lanyard_half_dia * [1,0])
525 circle(r= lanyard_half_dia/2);
529 module LanyardCurveChannelProfile(){
530 translate([0, -ly_r])
531 LanyardLanyardProfile();
534 module LanyardEntryChannelProfile(){
535 LanyardLanyardProfile(true);
538 module LanyardMainChannelProfile(){
539 LanyardCurveChannelProfile();
541 square(center=true, ly_r * [6, 2]);
543 translate(ly_r * [3 * xs, -1])
548 module LanyardEntryOuterProfile(){
549 circleat([ly_re + ly_r, 0], ly_re);
552 module LanyardEntry(){
558 translate([d_x, 0, q_z]) {
561 rotate_extrude(convexity=10)
564 LanyardCurveChannelProfile();
572 linear_extrude(height=20)
574 LanyardEntryChannelProfile();
576 translate([0, ly_r*2, 0])
578 linear_extrude(height = ly_r*4){
580 rectfromto([d_x, q_z], [ly_r, 0]);
581 circleat([d_x, q_z], ly_rc);
585 translate([0,0,q_z]){
588 translate([0, oec_y, 0]){
590 translate(ly_re * [-1,0,-2])
591 cube(ly_re * [2,1,2]);
592 rotate_extrude(convexity=10)
593 LanyardEntryOuterProfile();
598 translate([-ly_re, -(oec_y + 0.01), -2*ly_re])
599 cube([ly_re*2, 2*(oec_y + 0.01), 2*ly_re]);
604 linear_extrude(height=20)
605 LanyardEntryOuterProfile();
610 module LanyardCutout(l){
612 linear_extrude(height=l)
614 LanyardMainChannelProfile();
617 translate(ee * l * [-1,0])
623 module LidEdgeProfile(){
634 circleat(lpp12, r=lp_r12);
635 rectfromto( lpp12 + [-10, 0],
636 lpp12 + [+10, +10] );
640 module LidEdgeFoldClearanceProfile(){
641 translate([-lid_fold_clearance_antislop, 0])
650 module ButtonCoverProfile(){
652 polygon(concat([ bppM, bppP, bppO, bppJ ],
653 (enable_support && !$button_suppress_over_keeper
654 ? [ bppU, bppV, bppW ] : []),
663 module ButtonPlan(l, deep, cut){
665 (cut ? 0 : lid_buttoncover_gap);
668 (deep ? lid_buttoncover_overlap : 0);
670 C = [0,0]; // by definition
674 B0 = C + [0,-1] * button_cutout_depth;
675 B1 = B0 + [0,1] * epsilon;
677 r0 = 0.5 * (T[1] - B0[1]);
678 A = [ -(l + button_l_fudge)/2 + r0, 0.5 * (T[1] + B0[1]) ];
679 H = A + [0,-1] * delta;
685 E1 = E0 + [1,0] * epsilon;
687 I0 = [ E0[0], H[1] ];
688 I1 = [ E1[0], H[1] ];
691 for (m=[0,1]) mirror([m,0])
692 circleat(H, r0 - epsilon);
694 for (m=[0,1]) mirror([m,0]) {
704 circleat(D, r0 + epsilon);
709 module ButtonCoverReinf(){ ////toplevel
712 linear_extrude(height=0.01)
714 ButtonCoverProfile();
715 translate([bppJ[0] + 0.1, -50]) mirror([1,0])
718 mirror([0,0,1]) linear_extrude(height=0.01) intersection(){
719 circle(r= lid_buttoncover_reinf);
720 translate([-20,0]) square(40, center=true);
725 module ThumbRecessCutProfile(){
727 polygon([ cppA + [-10,0],
731 circleat(epp1, r=case_th_side);
735 module Flip_rhs(yn=[0,1]) {
737 translate([phone_width/2, 0, 0])
738 mirror([$rhsflip,0,0])
739 translate([-phone_width/2, 0, 0])
744 module Flip_bot(yn=[0,1]) {
746 translate([0, -phone_height/2, 0])
747 mirror([0, $botflip, 0])
748 translate([0, phone_height/2, 0])
753 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
756 translate([0, -phone_cnr_rad, 0])
758 linear_extrude(height = phone_height - phone_cnr_rad*2)
762 Flip_rhs() Flip_bot() {
763 translate([+1,-1] * phone_cnr_rad)
768 translate([-1,0] * phone_cnr_rad)
770 rectfromto([0,-20],[10,20]);
772 translate([-10, 0, -20] + 0.01 * [+1,-1, 0] )
778 translate([ phone_width - phone_cnr_rad, 0,0 ])
780 linear_extrude(height = phone_width - phone_cnr_rad*2)
784 translate([0,0, fill_zstart])
785 mirror([0,0, fill_downwards])
786 linear_extrude(height = fill_th)
787 rectfromto([+1,-1] * phone_cnr_rad,
788 [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
791 module CaseAperture(pos, dia, $fn) {
793 translate([ pos[0] + bumper[0],
796 rotate([-90, theta, 0])
797 cylinder(r = dia/2 / cos(theta),
801 module SideButton(y, y_ref_sign, l, suppress_over_keeper=0){
803 // +1 measured from top of actual phone to top of button
804 // -1 measured from bottom of actual phone to bottom of button
805 // 0 y is centre of button in coordinate system
807 $button_suppress_over_keeper= suppress_over_keeper;
808 eff_y = y_ref_sign > 0 ? -bumper [1] -y -l/2 :
809 y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
812 translate([0, eff_y, 0])
816 module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
817 $button_leg_only = true;
818 SideButton(y, y_ref_sign, l) children();
822 Flip_rhs(1) SideButton(30.320, +1, 22.960 ) children(); // volume
823 Flip_rhs(1) SideButton(64.220, +1, 14.500 ) children(); // power
824 Flip_rhs( ) LidButtonishLeg(14, -1) children();
825 Flip_rhs(0) LidButtonishLeg(14, +1) children();
826 // xxx need hole for whatever that hole is on lhs
829 module Struts(x_start, z_min, th){
830 // if th is negative, starts at z_min and works towards -ve z
831 // and object should then be printed other way up
832 for (i= [1 : 1 : case_struts_count]) {
836 mirror([0,0, th<0 ? 1 : 0])
838 -phone_height * i / (case_struts_count+1),
839 case_struts_solid_below])
840 linear_extrude(height= abs(th)
841 -(case_struts_solid_below+case_struts_solid_above))
842 rectfromto([ x_start, -0.5 * case_struts_width ],
843 [ phone_width - x_start, +0.5 * case_struts_width ]);
847 module OrdinaryRearAperture(rhs,bot, pos){
848 Flip_rhs(rhs) Flip_bot(bot)
851 translate(pos + bumper)
859 linextr(-epp2i[0], 60)
860 translate([0.5 * phone_width, 0, 0])
861 rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
862 [+microusb_width/2, epp0[1] + -microusb_above]);
866 module OrdinaryRearApertures(){
868 OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
869 rectfromto(-rearspeaker_gap,
870 rearspeaker_size + rearspeaker_gap);
872 // finger hole to remove phone
873 if (len(fingerpushhole_dias))
874 OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
876 scale(fingerpushhole_dias)
880 module RearCameraAperture(){
883 linear_extrude(height = 20)
886 rectfromto(camera_pos_tl, camera_pos_br);
889 module HingeLidProfile(){
891 circleat(hppT, hp_r1);
892 circleat(lpp12, lp_r12);
900 module HingeBaseProfile(){
903 circleat(hppB, hp_r1);
904 circleat(hppE, hp_r1);
905 circleat(epp2o, case_th_bottom);
906 circleat(hppB + [10,0], hp_r1);
908 polygon([epp5, epp1, epp3, bppL]);
912 module HingeLeverOuterProfile(){
914 circleat(hppT, hp_r2);
915 circleat(hppB, hp_r2);
919 module HingeLeverInnerProfile(){
921 c = s > 0 ? hppT : hppB;
924 rotate(s<0 ? -40 : 0)
933 module HingeLeverNutProfile(){
934 for (c= [hppB, hppT]) {
936 circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
940 module Flip_hinge(doflip=1){
941 hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
942 translate(hinge_origin)
943 rotate([doflip*180,0,0])
944 translate(-hinge_origin)
948 module HingePortion(x0,x1){
949 Flip_rhs() Flip_bot(1)
953 linear_extrude(height=x1-x0)
957 module ThumbRecessApply(ztop){
958 width = thumbrecess_width;
959 w = width + thumbrecess_topcurve_r*2 + 1;
960 translate([phone_width/2, 0,0]){
965 translate([0, 50, 0])
967 linear_extrude(height=100){
968 for (m=[0,1]) mirror([m,0,0]) {
970 translate([w/2, ztop - thumbrecess_topcurve_r])
971 circle(thumbrecess_topcurve_r);
972 translate([w/2, -50])
973 square(thumbrecess_topcurve_r*2, center=true);
982 AroundEdges(epp3[1], case_th_bottom, 1)
986 function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
988 module PropProfileAssignments(gamma){
989 // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
991 p = phone_height + prlp10[0] - hppB[0];
994 q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
996 c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
997 $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
999 $prp_theta = 90 - $prp_alpha;
1000 beta = 180 - $prp_alpha - gamma;
1003 //echo("abc", a,b,c);
1005 v1 = [ [ cos(psi), -sin(psi) ], // x
1006 [ sin(psi), cos(psi) ] ]; // y
1008 $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
1011 $prp_r11 = prop_main_th/2;
1013 $prpp1 = $prpp7 + [1,0] *
1014 // this is approximate, but will do
1015 (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
1018 v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
1019 $prpp12 = $prpp3 + v1[0] *
1020 (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
1021 $prp_r8 = prop_main_th;
1022 $prpp4 = [ prop_main_th/2, $prpp3[1] ];
1024 $prpp5 = [ $prpp12[0] - $prp_r5,
1025 $prpp3[1] - prop_prong_h + $prp_r5 ];
1026 $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
1027 prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
1028 $prpp8 = $prpp4 + [0,-1] * $prp_r8;
1029 $prpp9 = $prpp8 + [-1,0] * $prp_r8;
1034 module PropProfile(gamma, cut=0, rot=0){
1035 PropProfileAssignments(gamma){
1037 //#circleat($prpp3,1);
1038 //#circleat($prpp12,1);
1045 polygon([[-20,-0], [20,20], [0,0]]);
1047 rectfromto($prpp6, $prpp9);
1048 translate($prpp5) intersection(){
1050 polygon([[-10,-10], [0,0], [10,0]]);
1052 rectfromto($prpp12 + [0,-0.1], $prpp3);
1055 circleat($prpp1, $prp_r1);
1056 rectfromto($prpp12 + [0,-0.1], $prpp3);
1060 rotate([0,0, rot*-$prp_theta]){
1062 extra = cut ? prop_recess_slop : 0;
1063 rectfromto($prpp6, $prpp9);
1064 circleat($prpp11, $prp_r11 + extra);
1065 circleat($prpp10, $prp_r10 + extra);
1071 module PropAggregateProfile(){
1072 for (angle = prop_angles)
1073 PropProfile(angle, 0,0);
1076 module Prop(){ ////toplevel
1077 hw = prop_main_width/2;
1079 PropAggregateProfile();
1082 module Case(){ ////toplevel
1087 // ledge (fixed keeper)
1088 Flip_rhs(1-keeper_side) intersection(){
1090 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1093 // outline of the whole case, to stop it protruding
1094 translate([0,0, -25])
1095 linear_extrude(height = 50)
1098 circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
1102 HingePortion(hex20, hex21) HingeBaseProfile();
1104 // buildout for prop recess
1105 if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
1106 linextr(case_bottom_z, epp2i[1])
1109 circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
1111 r = epp2o[0] - prcp2[0]);
1116 Flip_rhs(keeper_side)
1117 translate([0, -phone_cnr_rad, 0])
1119 linear_extrude(height = phone_height + phone_cnr_rad * 2)
1122 rectfromto([ -keeper_gap_x, -keeper_gap_z_bot ],
1123 [ keeper_gap_x_holes, +keeper_gap_z_top ]);
1127 RearCameraAperture();
1129 // struts (invisible, because they're buried in the case)
1130 Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
1135 if (!($button_leg_only && enable_support))
1137 translate([0,0,-10])
1138 linear_extrude(height= 20)
1139 ButtonPlan($button_l, 0,1);
1140 if ($button_leg_only)
1142 translate([phone_width/2, -400, kppe[1]])
1143 mirror([1-abs($rhsflip - keeper_side),0,0])
1144 cube([400, 800, 50]);
1145 if (enable_support && !$button_suppress_over_keeper)
1147 translate([-400, -400, kppd[1]])
1149 cube([800,800,100]);
1151 translate([0,0, -bppR[0]])
1152 linear_extrude(height= 20)
1153 ButtonPlan($button_l, 1,1);
1158 // apertures along top edge
1159 if (!$suppress_forward_holes) {
1160 // CaseAperture(jack_pos, jack_dia, 8);
1162 CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 8);
1165 OrdinaryRearApertures();
1169 // gaps for the lid's hinge arms
1170 HingePortion(hex20 - hinge_x_arms_gap,
1171 hex21 + hinge_x_arms_gap)
1174 circle(r= hinge_r_arms_gap, $fn= 8);
1177 // screw holes in the hinge arms
1181 ThumbRecessApply(epp4[1])
1182 ThumbRecessCutProfile();
1186 translate([ly_o[0], -(phone_cnr_rad + ly_re), ly_o[1]])
1187 rotate([0, ly_theta, 0])
1189 LanyardCutout(lanyard_channel_len);
1193 translate([prop_x_pos,0,0])
1196 linextr(-prop_recess_hw, +prop_recess_hw)
1198 for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
1199 circleat(prcp1 + 20*d,
1205 module LidAdhocMultiprintFrame(phase){
1206 if (led_window_style >= 3) {
1207 AdhocMultiprintFrame(phase, lpp13[1], -1);
1211 module LidAroundEdges(){
1212 AroundEdges(lpp15[1], lpp13[1] - lpp15[1], 0)
1216 module Lid(){ ////toplevel
1217 skew_centre = [0, lpp11[0], lpp11[1]];
1224 translate(skew_centre)
1225 multmatrix([[ 1, 0, 0, 0 ],
1226 [ 0, 1, -lid_fold_clearance_skew, 0 ],
1229 translate(-skew_centre)
1231 LidEdgeFoldClearanceProfile();
1238 translate([0,0,-10])
1239 linear_extrude(height= 20)
1240 ButtonPlan($button_l, 1,0);
1243 translate([0,0,-100])
1244 linear_extrude(height= 200)
1245 ButtonCoverProfile();
1247 for (y= [-1,+1] * (($button_l + button_l_fudge)/2
1248 - lid_buttoncover_reinf))
1256 HingePortion(hex20, hex21) {
1261 Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
1263 // screw holes in the hinge arms
1267 translate([prop_x_pos, -prlp10[0], prlp10[1]])
1270 linextr(-prop_recess_hw, +prop_recess_hw)
1272 for (pa = prop_angles)
1273 PropProfile(pa, 1,1);
1275 // notification led aperture
1276 if (led_window_style)
1277 translate([led_pos[0], -led_pos[1], lpp13[1]]) {
1278 translate([0,0,-10])
1279 cylinder(r=nla_r0, h=20);
1280 if (led_window_style >= 2)
1281 translate([0,0, -nla_t])
1282 cylinder(r=nla_r2, height=20);
1287 LidAdhocMultiprintFrame(1);
1290 module HingeLever(){ ////toplevel
1292 // outer body, positive
1293 HingePortion(hex22, hex22 + phone_width/2)
1294 HingeLeverOuterProfile();
1296 // space for the screws
1297 HingePortion(hex26, hex24)
1298 HingeLeverInnerProfile();
1300 // recesses for the nuts
1301 HingePortion(hex23, hex26+1)
1302 HingeLeverNutProfile();
1304 // bores for the screws
1307 // space for the charging cable
1309 Flip_hinge() MicroUSB();
1313 module LidWindow(){ ////toplevel
1314 translate([led_pos[0], -led_pos[1], lpp13[1]])
1316 cylinder(r= nla_r1, h=nla_t);
1317 LidAdhocMultiprintFrame(0);
1320 module LidWindowPrint(){ ////toplevel
1325 module DemoLidWindowSelect(){
1326 translate([led_pos[0], led_pos[1], -100]) {
1327 translate([0, -30, 0]) cube([400, 400, 200]);
1331 module DemoLidWindow(){ ////toplevel
1334 translate([0,40,0]){
1335 color("blue") intersection(){ Lid(); DemoLidWindowSelect(); }
1336 color("red") intersection(){ LidWindow(); DemoLidWindowSelect(); }
1340 module HingeLeverPrint(){ ////toplevel
1342 translate([-phone_width/2, phone_height, 0])
1346 module TestSelectLength(){
1347 translate([-30, -200, -20])
1348 cube([30 + 15, 250, 40]);
1351 module TestLength(){ ////toplevel
1358 module TestLengthRight(){ ////toplevel
1366 module TestSelectWidth(){
1367 translate([-30, -(phone_height - 25), -20])
1369 cube([200, 50, 40]);
1372 module TestWidth(){ ////toplevel
1379 module TestLidWidthPrint(){ ////toplevel
1380 rotate([0,180.0]) intersection(){
1386 module TestSelectRearAperture(){
1389 translate([20, 0,0])
1390 cube([42, 2, 1], center=true);
1394 module TestSelectCamera(){
1396 TestSelectRearAperture()
1397 RearCameraAperture();
1398 cube([0.1, 50, 0.1]);
1402 module TestSelectOrdinaryRearApertures(){
1403 TestSelectRearAperture()
1404 OrdinaryRearApertures();
1407 module TestCamera(){ ////toplevel
1414 module TestLidByCamera(){ ////toplevel
1421 module TestLidByCameraPrint(){ ////toplevel
1422 rotate([180,0,0]) TestLidByCamera();
1425 module DemoByCamera(){ ////toplevel
1426 color("blue") TestLidByCamera();
1427 color("red") TestCamera();
1430 module OneKeeper(){ ////toplevel
1431 translate([0, -phone_cnr_rad, 0])
1433 linear_extrude(height = phone_height - phone_cnr_rad * 2)
1437 module OneKeeperPrint(){ ////toplevel
1442 module LidPrint(){ ////toplevel
1447 module TestSelectFrame(){
1448 include = [1,-1] * (epp2i[0] + 4);
1451 cube(1000, center=true);
1452 translate([0,0, -100])
1453 linear_extrude(height=200)
1454 rectfromto(include, inside_br - include);
1458 module TestSelectLidFrame(){
1460 translate([led_pos[0], -led_pos[1], -50])
1461 cylinder(r= nla_r2+3, h=100);
1464 module TestFrameCase(){ ////toplevel
1470 TestSelectOrdinaryRearApertures();
1475 module TestSelectTopApertures(){
1476 translate([-100, -35, -100])
1477 cube([400, 100, 200]);
1478 LidAdhocMultiprintFrame(0);
1479 LidAdhocMultiprintFrame(1);
1482 module TestTopApertures(){ ////toplevel
1486 TestSelectTopApertures();
1490 module TestLidTopAperturesPrint(){ ////toplevel
1491 rotate([0,180,0]) intersection(){
1493 TestSelectLidFrame();
1494 TestSelectTopApertures();
1498 module TestLidWindowTopAperturesPrint(){ ////toplevel
1499 rotate([0,180,0]) intersection(){
1501 TestSelectTopApertures();
1505 module TestFrameLidPrint(){ ////toplevel
1506 rotate([0,180,0]) intersection(){
1508 TestSelectLidFrame();
1512 module ButtonPlanForDemo(z, deep, cut){
1514 ButtonPlan(8, deep, cut);
1517 module HingeScrews(){
1518 Flip_rhs() Flip_bot(1){
1519 for (c= [ hppT, hppB ])
1524 translate([0,0,-.2])
1525 cylinder( r= hingescrew_shaft_dia/2,
1526 h = hingescrew_shaft_len+0.2 );
1528 translate([0,0,+.1])
1529 cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
1534 module DemoPropAngleSelect(c){
1535 color(c) difference(){
1536 union(){ children(); }
1537 translate([ prop_x_pos, -400, -200 ])
1538 cube([ 400,800,400 ]);
1542 module DemoPropAngle(ang){
1543 hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
1544 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1552 DemoPropAngleSelect("red") Case();
1555 translate([prop_x_pos, -prcp1[0], prcp1[1]])
1556 PropProfileAssignments(ang) {
1558 rotate([-$prp_theta, 0, 0])
1559 translate([0, $prpp1[0], -$prpp1[1]])
1565 translate([0,0, -hp_k*2])
1566 DemoPropAngleSelect("blue")
1570 module DemoPropAngles(){ ////toplevel
1571 for (i=[0 : len(prop_angles)-1])
1572 translate(i * [0, -100, 100])
1573 DemoPropAngle(prop_angles[i]);
1576 module DemoHingeAngle(ang1,ang2){
1577 hL = [0, -(phone_height - hppT[0]), hppT[1]];
1578 hC = [0, -(phone_height - hppB[0]), hppB[1]];
1589 color("blue") intersection(){
1592 translate([bppJ[0], -400, -200])
1594 cube([400, 800, 400]);
1595 translate([10, -400, -200])
1596 cube([10, 800, 400]);
1601 module DemoHingeAngles(){ ////toplevel
1602 angles = [ 0, 4, 8, 12 ];
1603 echo("angles",angles);
1604 for (i=[0 : len(angles)-1]) {
1605 translate(i * [0, 0, 30]) {
1606 DemoHingeAngle(0,angles[i]);
1607 translate([0, 200, 0])
1608 DemoHingeAngle(angles[i],0);
1613 module DemoSelectAdhocLeftRight(right=0) {
1614 translate([phone_width/2, -400, -100]) // , -15, -100 to cross-section
1615 mirror([1-right, 0,0])
1616 cube([400, 800, 200]);
1619 module DemoLeft(){ ////toplevel
1620 color("red") intersection(){ Case(); DemoSelectAdhocLeftRight(); }
1621 color("blue") intersection(){ Lid(); DemoSelectAdhocLeftRight(); }
1624 module DemoFrame(){ ////toplevel
1625 color("red") render() TestFrameCase();
1626 color("blue") render() intersection(){ Lid(); TestSelectLidFrame(); }
1627 color("black") render() HingeScrews();
1628 %render() HingeLever();
1631 module DemoLanyardCutout(){ ////toplevel
1635 module DemoHingedFrame(){ ///toplevel
1636 color("red") TestFrameCase();
1637 translate([0,0, -2*hp_k])
1638 color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
1641 color("orange") HingeLever();
1642 color("black") HingeScrews();
1646 module DemoHinge(){ ////toplevel
1647 translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
1649 translate([0,0, -hp_k*3])
1654 module DemoProfiles(){ ////toplevel
1658 translate([0,0,-1]) color("black") KeeperProfile(1);
1661 translate([0,0,+1]) color("purple") LanyardMainChannelProfile();
1662 translate([0,0,+2]) color("red") LanyardCurveChannelProfile();
1663 translate([0, ly_q_z]){
1664 translate([0,0,-1]) color("blue") LanyardEntryChannelProfile();
1665 translate([ly_oec_y,0,-2]) color("black") LanyardEntryOuterProfile();
1669 translate([0,0,-5]) color("white") translate(epp2i)
1671 rectfromto([-15, 0],
1672 [+15, -max_case_bottom_edge_thickness]);
1675 LanyardMainChannelProfile();
1676 translate([0,0,1]) color("purple") LanyardCurveChannelProfile();
1677 translate([0,0,-1]) color("red") LanyardEntryChannelProfile();
1684 demopoint_QR = [ bppS[0], bppQ[1] - 0.1];
1686 color("blue") ButtonCoverProfile();
1688 rectfromto(bppQ, demopoint_QR);
1689 rectfromto(bppR, demopoint_QR);
1693 translate([-20,0]) {
1694 color("black") ButtonPlanForDemo(-2, 0,1);
1695 color("red" ) ButtonPlanForDemo(-4, 1,1);
1696 color("blue") ButtonPlanForDemo(-6, 1,0);
1699 translate([0, -30]) {
1702 color("blue") HingeLidProfile();
1703 color("red") HingeBaseProfile();
1704 color("black") translate([0,0,-2]) HingeLeverOuterProfile();
1708 translate([-30, -60 + 30*f]) {
1709 translate([0,0,-4]) EdgeProfile();
1710 %translate([0,0,-10]) HingeBaseProfile();
1711 translate([0,-2] * f * hp_k) {
1712 translate([0,0,-4]) LidEdgeProfile();
1713 %translate([0,0,-10]) %HingeLidProfile();
1715 translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
1716 translate([0,0,-2]) color("black") HingeLeverOuterProfile();
1717 translate([0,0,0]) color("red") difference(){
1718 HingeLeverOuterProfile();
1719 HingeLeverInnerProfile();
1721 translate([0,0,3]) color("yellow") HingeLeverNutProfile();
1726 translate([20,-30]) {
1729 //translate([0,0,1]) ThumbRecessCutProfile();
1730 translate([0,0,+1]) color("red")
1731 difference(){ EdgeProfile(); ThumbRecessCutProfile(); }
1734 translate([40,-30]) {
1738 PropProfile(10, 1, 0);
1743 translate([60,-30]) {
1744 PropAggregateProfile();