build the actual case

2023-12-22 02:30:27 +00:00
parent 1fe5fd7285
commit 57a8a0595e
5 changed files with 142 additions and 77 deletions
--- a/bits.scad
+++ b/bits.scad
@@ -1,3 +1,4 @@
+include <defaults.scad>
 include <dimensions.scad>
 use <primitives.scad>

@@ -9,7 +10,7 @@ module Volume_(Depth, Box=false)
    pillX(Depth, VolumeLength, VolumeHeight, center=false);
  }
 }
-module Volume(Depth, Box=false)
+module Volume(Depth=2, Box=false)
 {
  translate([BodyWidth, VolumeMinY, VolumeMinZ]) Volume_(Depth, Box=Box);
 }
@@ -22,7 +23,7 @@ module Power_(Depth, Box=false)
    pillX(Depth, PowerLength, PowerHeight, center=false);
  }
 }
-module Power(Depth, Box=false)
+module Power(Depth=2, Box=false)
 {
  translate([BodyWidth, PowerMinY, PowerMinZ]) Power_(Depth, Box=Box);
 }
@@ -35,7 +36,7 @@ module Camera_(Depth, Box=false)
    pillZ(CameraWidth, CameraLength, Depth, center=false);
  }
 }
-module Camera(Depth, Box=false)
+module Camera(Depth=2, Box=false)
 {
  translate([CameraMinX, CameraMinY, BodyHeight]) Camera_(Depth, Box=Box);
 }
@@ -48,7 +49,7 @@ module Usb_(Depth, Box=false)
    pillY(UsbWidth, Depth, UsbHeight, center=false);
  }
 }
-module Usb(Depth, Box=false)
+module Usb(Depth=2, Box=false)
 {
  translate([BodyWidth/2 - UsbWidth/2, BodyLength-Depth, UsbMinZ]) Usb_(Depth, Box=Box);
 }
@@ -57,7 +58,7 @@ module Aux_(Depth)
 {
  cylinderY(d=3.5, h=Depth, center=false);
 }
-module Aux(Depth)
+module Aux(Depth=10)
 {
  translate([AuxMinX, 0, AuxMinZ]) Aux_(Depth);
 }
--- a/case.scad
+++ b/case.scad
@@ -1,54 +1,116 @@
+include <defaults.scad>
 include <dimensions.scad>
+use <bits.scad>
 use <phone.scad>
+use <primitives.scad>

-$fs = 1;
+// thickness of case walls
+Thickness = 2;
+// how large of cuts (radial) to make around each component
+MarginCamera = 2;
+MarginButtons = 2.5;
+MarginPorts = 5.5;
+// 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
+FrontOverhangX = 3;
+FrontOverhangTop = 3;
+FrontOverhangBot = 6;

-module plate(Margin, Thick=Height)
+// gives a 1cm margin around the whole body of the phone, but only in the xy plane.
+module _PhoneBulkLayer(tol=tol)
 {
-	translate([0,0,2]) hull() {
-		translate([(Length-Height-Margin)/2,(Width-Height-Margin)/2,0]) cylinder(d=Height, h=Thick);
-		translate([-(Length-Height-Margin)/2,(Width-Height-Margin)/2,0]) cylinder(d=Height, h=Thick);
-		translate([(Length-Height-Margin)/2,-(Width-Height-Margin)/2,0]) cylinder(d=Height, h=Thick);
-		translate([-(Length-Height-Margin)/2,-(Width-Height-Margin)/2,0]) cylinder(d=Height, h=Thick);
+  minkowski() {
+    PhoneBody();
+    cube([20, 20, tol], center=true);
  }
 }

+module _FrontFace(tol=tol) {
+  color("thistle")
  difference() {
+    translate([0, 0, -Thickness]) PhoneBody();
+    _PhoneBulkLayer(tol=tol);
+  };
+}
+
+/// we want to cutout a portion of the case to expose the touchscreen.
+/// but we don't want to cut out the entire front face.
+/// so, produce a "mask", of just that front-facing portion of the case we want to preserve:
+/// returns a mask which is -Thickness <= z <= 0, within tolerance
+module _FrontKeep(tol=tol) {
+  minkowski() {
+    // take the outline of the front face of the phone
+    difference() {
+      minkowski() {
+        cylinder(r=2*tol, h=tol, center=true);
+        _FrontFace();
+      };
+      minkowski() {
+        cylinder(r=tol, h=2*tol, center=true);
+        _FrontFace();
+      };
+    };
+    // and expand it
+    // cylinder(r=FrontOverhangX, h=tol, center=false);
+    // translate([0, -0.5*(FrontOverhangBot - FrontOverhangTop), -Thickness])
+    pillZ(2*FrontOverhangX, FrontOverhangBot + FrontOverhangTop, tol, center=true);
+  };
+}
+
+/// returns the region which we want to subtract from the case, in order to keep the front screen accessible.
+/// the returned cutout is strictly z <= 0,
+module _FrontCutout() {
+  difference() {
+    _FrontFace();
+    _FrontKeep();
+  };
+}
+
+module Case()
+{
+  color("DarkSlateGray")
+  difference() {
+    minkowski() {
+      sphere(d=Thickness);
+      // Phone(volume=false, power=false, camera=false);
+      PhoneBody();
+    }
    union() {
-		difference() {
-			phone(4);
-			plate(2);
-		}
-		translate([0,0,Height/2-4]) {
      minkowski() {
-				difference() {
-					plate(3,1);
-					translate([0,0,-1])plate(3.1,4);
-				}
-				sphere(2);
-			}
-		}
-	}
-	phone(Bits=1);
-	//translate([0,-50,-50])cube([100,100,100]);
-}
-
-/*
-translate([0,0,Height/2-4]) {
+        sphere(r=MarginCamera);
+        Camera();
+      };
+      // restrict these cutouts to just the phone bulk -- don't let them impact the back of the case
+      intersection() {
+        _PhoneBulkLayer();
+        union() {
          minkowski() {
-		difference() {
-			plate(3,1);
-			translate([0,0,-1])plate(3.1,4);
+            sphere(r=MarginButtons);
+            union() {
+              Volume();
+              Power();
+            };
+          }
+          minkowski() {
+            sphere(r=MarginPorts);
+            union() {
+              Usb();
+              Aux();
+            };
+          };
+        };
+      };
+      Phone(usb=false, aux=false);
+      translate([0, 0, tol]) _FrontCutout();
+      // _FrontCutout();
    }
-		sphere(2);
  }
 }

-	minkowski() {
-		difference() {
-			cube([Length+0.2, Width+0.2, 0.2], true);
-			cube([Length, Width, 4], true);
-		}
-		sphere(d=3);
-	}
-*/
+Case();
+
+// debugging:
+// _FrontFace();
+// _FrontKeep();
+// _FrontCutout();
+// Phone();
--- a/defaults.scad
+++ b/defaults.scad
@@ -0,0 +1,5 @@
+$fs = 1;
+
+// tolerance. lining up the extrusions and cuts with zero tolerance causes very thin walls,
+// so i offset those to make the model actually contiguous.
+tol = 0.01;
--- a/phone.scad
+++ b/phone.scad
@@ -1,53 +1,48 @@
+include <defaults.scad>
 include <dimensions.scad>
 use <bits.scad>
 use <primitives.scad>

-$fs = 1;
-
-// tolerance. lining up the extrusions and cuts with zero tolerance causes very thin walls,
-// so i offset those to make the model actually contiguous.
-Tol = 0.1;
-
-// simple box-shaped body; preserve for easier debugging
-module BodyBox() {
-  cube([BodyWidth, BodyLength, BodyHeight], center=false);
-}

 // return the kernel which can be convolved with the box body to produce the actual body
-module BodyConvolve(Tol=Tol) {
+module _BodyConvolve(tol=tol) {
  minkowski() {
    // cylinder rounds the four corners of the phone
-    cylinder(r=BodyRadXY-BodyRadFrontZ, h=Tol, center=true);
+    cylinder(r=BodyRadXY-BodyRadFrontZ, h=tol, center=true);
    // sphere rounds the thickness of the phone
    // in actuality this shouldn't be symmetric (the screen and back cover have different radii),
    // but using a single radius is Good Enough
    sphere(r=BodyRadFrontZ);
-    // cylinderY(r=BodyRadFrontZ, h=Tol, center=true);
-    // cylinderX(r=BodyRadFrontZ, h=Tol, center=true);
+    // cylinderY(r=BodyRadFrontZ, h=tol, center=true);
+    // cylinderX(r=BodyRadFrontZ, h=tol, center=true);
  }
 }

-module Body()
+module PhoneBody(Box=false)
 {
+  if (Box) {
+    cube([BodyWidth, BodyLength, BodyHeight], center=false);
+  } else {
    translate([BodyRadXY, BodyRadXY, BodyRadFrontZ])
    minkowski() {
      cube([BodyWidth-2*BodyRadXY, BodyLength-2*BodyRadXY, BodyHeight-2*BodyRadFrontZ], center=false);
-    BodyConvolve();
+      _BodyConvolve();
+    }
  }
 }

-module Phone(Box=false)
+module Phone(Box=false, volume=true, power=true, camera=true, usb=true, aux=true)
 {
  difference() {
    union() {
-      if (Box) { BodyBox(); } else { Body(); }
-      Volume(2, Box=Box);
-      Power(2, Box=Box);
-      Camera(2, Box=Box);
+      PhoneBody(Box=Box);
+      if (volume) { Volume(Box=Box); }
+      if (power) { Power(Box=Box); }
+      if (camera) { Camera(Box=Box); }
    }
    union() {
-      translate([0, Tol, 0])Usb(2, Box=Box);
-      translate([0, -Tol, 0])Aux(2);
+      if (usb) { translate([0, tol, 0]) Usb(Box=Box); }
+      if (aux) { translate([0, -tol, 0]) Aux(); }
    }
  }
 }
--- a/primitives.scad
+++ b/primitives.scad
@@ -1,5 +1,7 @@
 //! general-purpose "primitives" lacking from the OpenSCAD builtins

+include <defaults.scad>
+
 /// 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)
@@ -27,7 +29,7 @@ module cylinderZ(d=undef, r=undef, h=undef, center=false) {
 }

 // a 2d-cylinder extruded along the x-axis
-module pillX(dimX, dimY, dimZ, tol=0.01, center=false) {
+module pillX(dimX, dimY, dimZ, tol=tol, center=false) {
  diam = min(dimY, dimZ) - tol;
  minkowski() {
    cube([dimX/2, dimY-diam, dimZ-diam], center=center);
@@ -36,7 +38,7 @@ module pillX(dimX, dimY, dimZ, tol=0.01, center=false) {
 }

 // a 2d-cylinder extruded along the x-axis
-module pillY(dimX, dimY, dimZ, tol=0.01, center=false) {
+module pillY(dimX, dimY, dimZ, tol=tol, center=false) {
  diam = min(dimX, dimZ) - tol;
  minkowski() {
    cube([dimX-diam, dimY/2, dimZ-diam], center=center);
@@ -45,7 +47,7 @@ module pillY(dimX, dimY, dimZ, tol=0.01, center=false) {
 }

 // a 2d-cylinder extruded along the z-axis
-module pillZ(dimX, dimY, dimZ, tol=0.01, center=false) {
+module pillZ(dimX, dimY, dimZ, tol=tol, center=false) {
  diam = min(dimX, dimY) - tol;
  minkowski() {
    cube([dimX-diam, dimY-diam, dimZ/2], center=center);