fix to avoid coincident edges that mess up OpenSCAD meshes

src/case.scad

@@ -1,67 +1,76 @@
 include <lib/defaults.scad>
 use <lib/primitives.scad>
+use <lib/transformations.scad>
 
 // thickness of case walls
-Thickness = 3.5;
+Thickness = 2.5;
 // how large of cuts (radial) to make around each component
 MarginCameraCut = 2;
 MarginButtonsCut = 2.8;
-MarginPortsCut = 5.5;
+MarginPortsCut = 7.0;
 
-MarginButtonsSeat = 1.5;
+// radial margin; this value (halved) becomes the margin for thickness
+MarginButtonsSeat = 1.4;
 // 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
-FrontOverhangX = 4;
+FrontOverhangX = 3;
-FrontOverhangTop = 5;
+FrontOverhangTop = 3.5;
-FrontOverhangBot = 7;
+FrontOverhangBot = 6;
 // shift the overhang into the screen, to account that the case has some flex
 FrontSquashZ = 1.2;
 
-// gives a 1cm margin around the whole body of the phone, but only in the xy plane.
+// gives a wide margin around the whole body of the phone, but only in the xy plane.
-module _PhoneBulkLayer(tol=tol)
+module _PhoneBulkLayer(zMin=0)
 {
-  minkowski() {
+  hull() {
-    children(/*body*/);
+    translate([-500, -500, zMin]) extractZDomain() children(/*body*/);
-    cube([20, 20, tol], center=true);
+    translate([ 500, -500, zMin]) extractZDomain() children(/*body*/);
-  }
+    translate([ 500,  500, zMin]) extractZDomain() children(/*body*/);
+    translate([-500,  500, zMin]) extractZDomain() children(/*body*/);
+  };
 }
 
-/// gives as 1cm margin around the whole body of the phone,
+/// gives a margin around the whole body of the phone,
-/// on all axis EXCEPT the -z axis
+/// on all axes EXCEPT the -z axis
-module _PhoneBulkAndBack()
+module _PhoneBulkAndBack(zMin=0)
 {
-  minkowski() {
+  hull() {
-    children(/*body*/);
+    _PhoneBulkLayer(zMin=zMin) children(/*body*/);
-    translate([0, 0, 5+tol]) cube([20, 20, 10], center=true);
+    translate([0, 0, 10]) _PhoneBulkLayer(zMin=zMin) children(/*body*/);
   }
 }
 
 module _DilatedBody(ButtonStyle) {
   body = 0;
   buttons = 1;
+  union() {
     minkowski() {
       sphere(r=Thickness);
-    union() {
       children(body);
+    };
     if (ButtonStyle == "extrude") {
+      minkowski() {
+        sphere(r=Thickness);
+        // cylinderX(r=Thickness, h=2*Thickness, center=true);
         children(buttons);
       };
     }
-  }
+  };
 }
 
-module _DilatedBodyExceptFront(ButtonStyle) {
+module _DilatedBodyExceptFront(ButtonStyle, zMin=0) {
   body = 0;
   buttons = 1;
   intersection() {
-    _DilatedBody() {
+    _DilatedBody(ButtonStyle=ButtonStyle) {
       children(body);
       children(buttons);
     };
-    _PhoneBulkAndBack() children(body);
+    _PhoneBulkAndBack(zMin=zMin) children(body);
   }
 }
 
+/// returns the geometry which should be removed from the case, to make room for ports/buttons
 module _PeripheralCutouts(ButtonStyle) {
   body = 0;
   buttons = 1;
@@ -69,7 +78,8 @@ module _PeripheralCutouts(ButtonStyle) {
   camera = 3;
   union() {
     minkowski() {
-      sphere(r=MarginCameraCut);
+      // sphere(r=MarginCameraCut);
+      cylinderZ(r=MarginCameraCut, h=2*Thickness+tol, center=true);
       children(camera);
     };
     // restrict these cutouts to just the phone bulk -- don't let them impact the back of the case
@@ -84,6 +94,7 @@ module _PeripheralCutouts(ButtonStyle) {
         };
         minkowski() {
           sphere(r=MarginPortsCut);
+          // cylinderY(r=MarginPortsCut, h=2*MarginPortsCut, center=true);
           children(ports);
         };
       };
@@ -91,11 +102,11 @@ module _PeripheralCutouts(ButtonStyle) {
   };
 };
 
-module _FrontFace(tol=tol) {
+module _FrontFace() {
   color("thistle")
   difference() {
     translate([0, 0, -Thickness]) children(/*body*/);
-    _PhoneBulkLayer(tol=tol) children(/*body*/);
+    _PhoneBulkLayer() children(/*body*/);
   };
 }
 
@@ -107,6 +118,7 @@ module _FrontKeep(tol=tol) {
   minkowski() {
     // take the outline of the front face of the phone
     difference() {
+      // TODO: projection, then hull
       minkowski() {
         cylinder(r=2*tol, h=tol, center=true);
         _FrontFace() children(/*body*/);
@@ -123,23 +135,15 @@ module _FrontKeep(tol=tol) {
   };
 }
 
-/// returns the region which we want to subtract from the case, in order to keep the front screen accessible.
+/// complete case except for cutouts
-/// the returned cutout is strictly z <= 0,
+module _CaseExceptFeatures(ButtonStyle, tol=tol)
-module _FrontCutout() {
-  difference() {
-    _FrontFace() children(/*body*/);
-    _FrontKeep() children(/*body*/);
-  };
-}
-
-module _CaseExceptFeatures(ButtonStyle)
 {
   body = 0;
   buttons = 1;
   union() {
     difference() {
       // start by dilating the phone
-      _DilatedBodyExceptFront(ButtonStyle=ButtonStyle) {
+      _DilatedBodyExceptFront(ButtonStyle=ButtonStyle, zMin=tol) {
         children(body);
         children(buttons);
       };
@@ -149,7 +153,7 @@ module _CaseExceptFeatures(ButtonStyle)
     // add in the front part of the case
     intersection() {
       _FrontKeep() translate([0, 0, FrontSquashZ]) children(body);
-      _DilatedBody() {
+      _DilatedBody(ButtonStyle=ButtonStyle) {
         children(body);
         children(buttons);
       };
@@ -197,13 +201,13 @@ module _Case(ButtonStyle)
 /// ```
 ///
 /// replace "Phone" above with the specific model, e.g. `PP` like `PPBody()`
-module Case(ButtonStyle="extrude", RenderPhone=false) {
+module Case(ButtonStyle="extrude", RenderPhone=false, OrientForPrint=true) {
   body = 0;
   buttons = 1;
   ports = 2;
   camera = 3;
-  // translate([PPBodyWidth + Thickness, Thickness, PPBodyHeight + Thickness])
+
-  rotate(a=[0, 180, 0])
+  _MaybeOrientForPrint(OrientForPrint)
   union() {
     color("DarkSlateGray") _Case(ButtonStyle) {
       children(body);
@@ -223,3 +227,16 @@ module Case(ButtonStyle="extrude", RenderPhone=false) {
     };
   };
 }
+
+module _MaybeOrientForPrint(OrientForPrint) {
+  if (OrientForPrint) {
+    // XXX these translations deform the mesh, slightly.
+    //     it should export OK, but if rendering gives errors about the mesh not being solid,
+    //     then clear cache and re-render (F6)
+    translateToAxis(x="pos", z="pos")
+    rotate([0, 180, 0])
+    children(0);
+  } else {
+    children(0);
+  };
+}

src/cases/pp.scad

@@ -1,7 +1,7 @@
 use <../case.scad>
 use <../pp/exports.scad>
 
-Case(RenderPhone=false) {
+Case(RenderPhone=false, OrientForPrint=true) {
   PPBody();
   PPButtons();
   PPPorts();

src/lib/primitives.scad

@@ -2,12 +2,14 @@
 
 include <defaults.scad>
 
+module empty() {}
+
 /// cylinder() but with the axis on the x axis instead of the z axis.
 /// and where `center=false` behaves like for `cube(center=false)`,
 ///   i.e. circle center is not at (0, 0) but (r, r)
 module cylinderX(d=undef, r=undef, h=undef, center=false) {
   _translateIf(!center, [0, _toRad(r=r, d=d), _toRad(r=r, d=d)]) {
-    rotate(a=[0,-90,0]) cylinder(d=d, r=r, h=h, center=center);
+    rotate(a=[0,90,0]) cylinder(d=d, r=r, h=h, center=center);
   }
 }
 
@@ -28,30 +30,62 @@ module cylinderZ(d=undef, r=undef, h=undef, center=false) {
   }
 }
 
-// a 2d-cylinder extruded along the x-axis
+// a 2d-cylinder normal to the x axis, and elongated over the y/z axis.
-module pillX(dimX, dimY, dimZ, tol=tol, center=false) {
+module pillX(dimX, dimY, dimZ, center=false) {
-  diam = min(dimY, dimZ) - tol;
+  diam = min(dimY, dimZ);
-  minkowski() {
+  hull() {
-    cube([dimX/2, dimY-diam, dimZ-diam], center=center);
+    cylinderX(d=diam, h=dimX, center=center);
-    cylinderX(d=diam, h=dimX/2, center=center);
+    translate([0, dimY-diam, dimZ-diam]) cylinderX(d=diam, h=dimX, center=center);
+  };
+}
+
+// a 2d-cylinder normal to the y axis, and elongated over the x/z axis.
+module pillY(dimX, dimY, dimZ, center=false) {
+  diam = min(dimX, dimZ);
+  hull() {
+    cylinderY(d=diam, h=dimY, center=center);
+    translate([dimX-diam, 0, dimZ-diam]) cylinderY(d=diam, h=dimY, center=center);
+  };
+}
+
+// a 2d-cylinder normal to the z axis, and elongated over the x/y axis.
+module pillZ(dimX, dimY, dimZ, center=false) {
+  diam = min(dimX, dimY);
+  hull() {
+    cylinderZ(d=diam, h=dimZ, center=center);
+    translate([dimX-diam, dimY-diam, 0]) cylinderZ(d=diam, h=dimZ, center=center);
+  };
+}
+
+module sphere_(r, align=undef, alignX=undef, alignY=undef, alignZ=undef) {
+  alignX_ = _default(alignX, align);
+  alignY_ = _default(alignY, align);
+  alignZ_ = _default(alignZ, align);
+
+  sX = _selectScale(alignX);
+  sY = _selectScale(alignY);
+  sZ = _selectScale(alignZ);
+
+  translate([r * sX, r * sY, r * sZ]) sphere(r=r);
+}
+
+function _default(primary, secondary) = (primary != undef) ? primary : secondary;
+
+function _selectScale(align) = (align == "center") ? 0 : ((align == "bbox") ? 1 : 0.707);
+
+/// a hollowed-out sphere
+module sphereShell(r, thickness) {
+  difference() {
+    sphere(r=r+thickness/2);
+    sphere(r=r-thickness/2);
   }
 }
 
-// a 2d-cylinder extruded along the x-axis
+/// a hollowed-out cube
-module pillY(dimX, dimY, dimZ, tol=tol, center=false) {
+module cubeShell(x, y, z, thickness, center=false) {
-  diam = min(dimX, dimZ) - tol;
+  difference() {
-  minkowski() {
+    cube([x+thickness/2, y+thickness/2, z+thickness/2], center=center);
-    cube([dimX-diam, dimY/2, dimZ-diam], center=center);
+    cube([x-thickness/2, y-thickness/2, z-thickness/2], center=center);
-    cylinderY(d=diam, h=dimY/2, center=center);
-  }
-}
-
-// a 2d-cylinder extruded along the z-axis
-module pillZ(dimX, dimY, dimZ, tol=tol, center=false) {
-  diam = min(dimX, dimY) - tol;
-  minkowski() {
-    cube([dimX-diam, dimY-diam, dimZ/2], center=center);
-    cylinderZ(d=diam, h=dimZ/2, center=center);
   }
 }
 

src/lib/transformations.scad

@@ -0,0 +1,160 @@
+include <defaults.scad>
+
+/// projects the child onto the x axis, making it effectively 1 dimensional.
+/// actually, the result is a 3d "line" of thickness `tol` centered about the x axis.
+/// the x bounds are precise (regardless of tol): it's only the y/z thickness which requires tolerance)
+module extractXDomain(tol=tol) {
+  translate([0, -tol/2, -tol/2])
+    // compress (x,y=[0,tol],z) -> (x,y=[0,tol],z=[0,tol]
+    linear_extrude(tol) projection(cut=false)
+    // rotate so it's (x,z), with y in [0, tol]
+    rotate([-90, 0, 0])
+    // compress (x,y,z) -> (x,y,z=[0,tol])
+    linear_extrude(tol) projection(cut=false)
+    children(0);
+}
+
+/// creates a dot of size `tol` at (x=<the minimum x coordinate occupied by the child module>, y=0, z=0>
+module extractXMin(tol=tol) {
+  difference() {
+    translate([-tol/2, 0, 0]) extractXDomain(tol=tol) children(0);
+    translate([tol/2, 0, 0]) extractXDomain(tol=tol) children(0);
+  }
+}
+
+/// creates a dot of size `tol` at (x=<the maximum x coordinate occupied by the child module>, y=0, z=0>
+module extractXMax(tol=tol) {
+  difference() {
+    translate([tol/2, 0, 0]) extractXDomain(tol=tol) children(0);
+    translate([-tol/2, 0, 0]) extractXDomain(tol=tol) children(0);
+  }
+}
+
+/// translates the child so that its lowest x value is 0.
+module translateToX0Pos(tol=tol) {
+  minkowski() {
+    // flip about yz plane, so that we're shifting by -(lower_x_bound)
+    mirror([1, 0, 0]) extractXMin(tol=tol) children(0);
+    children(0);
+  }
+}
+
+/// translates the child so that its highest x value is 0.
+module translateToX0Neg(tol=tol) {
+  minkowski() {
+    // flip about yz plane, so that we're shifting by -(upper_x_bound)
+    mirror([1, 0, 0]) extractXMax(tol=tol) children(0);
+    children(0);
+  }
+}
+
+
+/// projects the child onto the y axis, making it effectively 1 dimensional.
+/// actually, the result is a 3d "line" of thickness `tol` centered about the y axis.
+module extractYDomain(tol=tol) {
+  rotate([0, 0, 90])
+  extractXDomain(tol=tol) {
+    rotate([0, 0, -90]) children(0);
+  }
+}
+
+/// creates a dot of size `tol` at (x=0, y=<the minimum y coordinate occupied by the child module>, z=0).
+module extractYMin(tol=tol) {
+  difference() {
+    translate([0, -tol/2, 0]) extractYDomain(tol=tol) children(0);
+    translate([0,  tol/2, 0]) extractYDomain(tol=tol) children(0);
+  }
+}
+
+/// creates a dot of size `tol` at (x=0, y=<the maximum y coordinate occupied by the child module>, 0).
+module extractYMax(tol=tol) {
+  difference() {
+    translate([0,  tol/2, 0]) extractYDomain(tol=tol) children(0);
+    translate([0, -tol/2, 0]) extractYDomain(tol=tol) children(0);
+  }
+}
+
+/// translates the child so that its lowest y value is 0.
+module translateToY0Pos(tol=tol) {
+  minkowski() {
+    // flip about xz plane, so that we're shifting by -(lower_y_bound)
+    mirror([0, 1, 0]) extractYMin(tol=tol) children(0);
+    children(0);
+  }
+}
+
+/// translates the child so that its highest x value is 0.
+module translateToY0Neg(tol=tol) {
+  minkowski() {
+    // flip about xz plane, so that we're shifting by -(upper_y_bound)
+    mirror([0, 1, 0]) extractYMax(tol=tol) children(0);
+    children(0);
+  }
+}
+
+
+/// projects the child onto the z axis, making it effectively 1 dimensional.
+/// actually, the result is a 3d "line" of thickness `tol` centered about the z axis.
+module extractZDomain(tol=tol) {
+  rotate([0, 90, 0])
+  extractXDomain(tol=tol) {
+    rotate([0, -90, 0]) children(0);
+  }
+}
+
+/// creates a dot of size `tol` at (x=0, y=0, z=<the minimum z coordinate occupied by the child module>).
+module extractZMin(tol=tol) {
+  difference() {
+    translate([0, 0, -tol/2]) extractZDomain(tol=tol) children(0);
+    translate([0, 0,  tol/2]) extractZDomain(tol=tol) children(0);
+  }
+}
+
+/// creates a dot of size `tol` at (x=0, y=0, z=<the maximum z coordinate occupied by the child module>).
+module extractZMax(tol=tol) {
+  difference() {
+    translate([0, 0,  tol/2]) extractZDomain(tol=tol) children(0);
+    translate([0, 0, -tol/2]) extractZDomain(tol=tol) children(0);
+  }
+}
+
+/// translates the child so that its lowest z value is 0.
+module translateToZ0Pos(tol=tol) {
+  minkowski() {
+    // flip about xy plane, so that we're shifting by -(lower_z_bound)
+    mirror([0, 0, 1]) extractZMin(tol=tol) children(0);
+    children(0);
+  }
+}
+
+/// translates the child so that its highest z value is 0.
+module translateToZ0Neg(tol=tol) {
+  minkowski() {
+    // flip about xy plane, so that we're shifting by -(upper_z_bound)
+    mirror([0, 0, 1]) extractZMax(tol=tol) children(0);
+    children(0);
+  }
+}
+
+module translateToAxis(x=undef, y=undef, z=undef, tol=tol) {
+  minkowski() {
+    minkowski() {
+      if (x == "neg") {
+        mirror([1, 0, 0]) extractXMax(tol=tol) children(0);
+      } else if (x == "pos") {
+        mirror([1, 0, 0]) extractXMin(tol=tol) children(0);
+      }
+      if (y == "neg") {
+        mirror([0, 1, 0]) extractYMax(tol=tol) children(0);
+      } else if (y == "pos") {
+        mirror([0, 1, 0]) extractYMin(tol=tol) children(0);
+      }
+      if (z == "neg") {
+        mirror([0, 0, 1]) extractZMax(tol=tol) children(0);
+      } else if (z == "pos") {
+        mirror([0, 0, 1]) extractZMin(tol=tol) children(0);
+      }
+    };
+    children(0);
+  }
+}

src/pp/exports.scad

@@ -3,22 +3,22 @@
 use <phone.scad>
 use <bits.scad>
 
-module PPButtons(volume=true, power=true) {
+module PPButtons(volume=true, power=true, box=false) {
   union() {
-    if (volume) Volume();
+    if (volume) Volume(Box=box);
-    if (power) Power();
+    if (power) Power(Box=box);
   };
 }
 
-module PPPorts(usb=true, aux=true) {
+module PPPorts(usb=true, aux=true, box=false) {
   union() {
-    if (usb) Usb();
+    if (usb) Usb(Box=box);
     if (aux) Aux();
   };
 }
 
-module PPCamera() {
+module PPCamera(box=false) {
-  Camera();
+  Camera(Box=box);
 }
 
 module PPBody(box=false) {

src/pp/phone.scad

@@ -19,16 +19,26 @@ module _BodyConvolve(tol=tol) {
   }
 }
 
+/// represents one corner of the body
+module _BodyPill() {
+  union() {
+    translate([BodyRadXY, BodyRadXY, BodyRadFrontZ]) rotate_extrude() translate([BodyRadXY - BodyRadFrontZ, 0, 0]) circle(r=BodyRadFrontZ);
+    translate([BodyRadXY, BodyRadXY, BodyHeight-BodyRadFrontZ]) rotate_extrude() translate([BodyRadXY - BodyRadFrontZ, 0, 0]) circle(r=BodyRadFrontZ);
+  }
+}
+
 module Body(Box=false)
 {
   if (Box) {
     cube([BodyWidth, BodyLength, BodyHeight], center=false);
   } else {
-    translate([BodyRadXY, BodyRadXY, BodyRadFrontZ])
+    hull() {
-    minkowski() {
+      // body is a `hull` over four pill-shaped corners
-      cube([BodyWidth-2*BodyRadXY, BodyLength-2*BodyRadXY, BodyHeight-2*BodyRadFrontZ], center=false);
+      _BodyPill();
-      _BodyConvolve();
+      translate([BodyWidth-2*BodyRadXY, 0, 0]) _BodyPill();
-    }
+      translate([BodyWidth-2*BodyRadXY, BodyLength-2*BodyRadXY, 0]) _BodyPill();
+      translate([0, BodyLength-2*BodyRadXY, 0]) _BodyPill();
+    };
   }
 }