create a trivial case from the phone model

missing cutouts for ports and extrusions for buttons

cq_toplevel.py

@@ -15,10 +15,15 @@ import sys
 
 sys.path.append(os.path.join(os.getcwd(), "src"))
 
+import case
 import pinephone
 
 logger = logging.getLogger(__name__)
 
+def model():
+    phone = pinephone.PinePhone()
+    return case.case(phone)
+
 def main():
     logging.basicConfig()
     logging.getLogger().setLevel(logging.INFO)
@@ -28,14 +33,14 @@ def main():
 
     args = parser.parse_args()
 
-    model = pinephone.PinePhone()
+    model_ = model()
 
     if args.export_stl:
         logger.info("exporting stl to %s", args.export_stl)
-        cq.exporters.export(model, args.export_stl)
+        cq.exporters.export(model_, args.export_stl)
 
 
 if __name__ == "__main__":
     main()
 else:
-    result = pinephone.PinePhone()
+    result = model()

src/case.py

@@ -0,0 +1,48 @@
+# thickness of case walls
+thickness = 1.5
+
+# how far into the xy plane to extend the part of the case which covers the front of the phone.
+# the top of the phone contains stuff we don't want to cover (camera); the bottom has more margin
+overhang_leftright = 2
+overhang_top = 2
+overhang_bot = 3.5
+# how much to smooth the overhangs, else the main opening in front appears rectangular
+overhang_radius = 2
+
+def _makeShell(solid, thickness: float=1, combine=False, **kwargs):
+    """
+    dilate the solid in all dimensions by `thickness` and then subtract the original.
+    this implementation only behaves as expected if the solid has no cusps (i.e. is smoothed).
+    so for boxes, one should fillet the edges first (even if fillet'd with a trivial radius).
+    """
+    # alternatively, to perform an inset, set thickness negative and use combine="cut"
+    return solid.faces().each(lambda f: f.thicken(thickness), combine=combine)
+
+def front_cutaway(case):
+    # split the case into the front part, which covers the screen, and the rear
+    split_case = case.faces("<<Z").workplane(offset=-thickness).split(keepTop=True, keepBottom=True)
+    case_front, case_back = split_case.all()
+    # front_face is a closed face capturing the full width/height of the case at z=0
+    front_face = case_front.faces(">Z")
+    # we only want to cutaway this smaller part of the front face
+    front_face_cutaway = (front_face
+        .intersect(front_face.translate((thickness + overhang_leftright, 0, 0)))
+        .intersect(front_face.translate((-(thickness + overhang_leftright), 0, 0)))
+        .intersect(front_face.translate((0, thickness + overhang_top, 0)))
+        .intersect(front_face.translate((0, -thickness - overhang_bot, 0)))
+    )
+    # "extrude" the front_face_cutaway into something thick enough to actually cut out
+    # N.B.: i think this logic isn't 100% correct
+    return front_face_cutaway.faces("|Z").each(lambda f: f.thicken(-thickness), combine=False) \
+        .edges("|Z").fillet(overhang_radius)
+    # front_cutaway = front_face_cutaway.faces("|Z").each(lambda f: f.thicken(thickness).translate((0, 0, -thickness)), combine=False)
+
+
+def case(phone):
+    # the entire case, before cutting anything away:
+    case = _makeShell(phone.solids(tag="body"), thickness)
+    case = case.cut(front_cutaway(case))
+    # TODO: compress the case along the Z axis, to give a snugger fit (0.8mm is a good compression)
+    # TODO: cut out the camera, aux, USB.
+    # TODO: add in volume/power buttons
+    return case

src/pinephone.py

@@ -52,19 +52,20 @@ def body():
     return (
         cq.Workplane("front")
         .box(body_width, body_length, body_height, centered=False)
-        .tag("body")
+        .tag("body_box")
         .faces(">>X").tag("body_right")
-        .faces(tag="body")
+        .faces(tag="body_box")
         .faces("<<Y").tag("body_top")
-        .faces(tag="body")
+        .faces(tag="body_box")
         .faces(">>Y").tag("body_bottom")
-        .faces(tag="body")
+        .faces(tag="body_box")
         .faces(">>Z").tag("body_back")
-        .faces(tag="body")
+        .faces(tag="body_box")
         .edges("|Z")
         .fillet(body_rad_xy)
         .edges("(|X or |Y)")
         .fillet(body_rad_front_z)
+        .tag("body")
     )
 
 def volume(body):
@@ -74,9 +75,12 @@ def volume(body):
         .workplane()
         .move(volume_min_y, volume_min_z)
         .box(volume_length, volume_height, volume_width, centered=False, combine=False)
-        .tag("volume")
+        .tag("volume_box")
         .edges("|X")
         .fillet(volume_height/3)  #< XXX: cadquery doesn't allow a full 1/2 fillet
+        # .edges("|Y")
+        # .fillet(volume_width/3)
+        .tag("volume")
     )
 
 def power(body):
@@ -86,9 +90,10 @@ def power(body):
         .workplane()
         .move(power_min_y, power_min_z)
         .box(power_length, power_height, power_width, centered=False, combine=False)
-        .tag("volume")
+        .tag("power_box")
         .edges("|X")
         .fillet(power_height/3)  #< XXX: cadquery doesn't allow a full 1/2 fillet
+        .tag("power")
     )
 
 def camera(body):
@@ -98,9 +103,10 @@ def camera(body):
         .workplane()
         .move(camera_min_x, camera_min_y)
         .box(camera_width, camera_length, 2, centered=False, combine=False)
-        .tag("camera")
+        .tag("camera_box")
         .edges("|Z")
         .fillet(camera_length/3)
+        .tag("camera")
     )
 
 def aux(body):
@@ -120,9 +126,10 @@ def usb(body):
         .workplane(offset=-10)
         .move(-body_width/2, usb_min_z)
         .box(usb_width, usb_height, 10, centered=(True, False, False), combine=False)
-        .tag("usb")
+        .tag("usb_box")
         .edges("|Y")
         .fillet(usb_height/3)
+        .tag("usb")
     )
 
 def PinePhone():