shift the front portions of the case "into" the phone, for a tighter fit

src/case.scad

@@ -14,6 +14,8 @@ MarginButtonsSeat = 1.5;
 FrontOverhangX = 4;
 FrontOverhangTop = 5;
 FrontOverhangBot = 7;
+// 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.
 module _PhoneBulkLayer(tol=tol)
@@ -24,6 +26,16 @@ module _PhoneBulkLayer(tol=tol)
   }
 }
 
+/// gives as 1cm margin around the whole body of the phone,
+/// on all axis EXCEPT the -z axis
+module _PhoneBulkAndBack()
+{
+  minkowski() {
+    children(/*body*/);
+    translate([0, 0, 5+tol]) cube([20, 20, 10], center=true);
+  }
+}
+
 module _DilatedBody(ButtonStyle) {
   body = 0;
   buttons = 1;
@@ -38,6 +50,18 @@ module _DilatedBody(ButtonStyle) {
   }
 }
 
+module _DilatedBodyExceptFront(ButtonStyle) {
+  body = 0;
+  buttons = 1;
+  intersection() {
+    _DilatedBody() {
+      children(body);
+      children(buttons);
+    };
+    _PhoneBulkAndBack() children(body);
+  }
+}
+
 module _PeripheralCutouts(ButtonStyle) {
   body = 0;
   buttons = 1;
@@ -108,6 +132,31 @@ module _FrontCutout() {
   };
 }
 
+module _CaseExceptFeatures(ButtonStyle)
+{
+  body = 0;
+  buttons = 1;
+  union() {
+    difference() {
+      // start by dilating the phone
+      _DilatedBodyExceptFront(ButtonStyle=ButtonStyle) {
+        children(body);
+        children(buttons);
+      };
+      // subtract the phone
+      children(body);
+    }
+    // add in the front part of the case
+    intersection() {
+      _FrontKeep() translate([0, 0, FrontSquashZ]) children(body);
+      _DilatedBody() {
+        children(body);
+        children(buttons);
+      };
+    };
+  };
+}
+
 module _Case(ButtonStyle)
 {
   body = 0;
@@ -115,28 +164,23 @@ module _Case(ButtonStyle)
   ports = 2;
   camera = 3;
   difference() {
-    // start by dilating the phone
-    _DilatedBody(ButtonStyle=ButtonStyle) {
+    _CaseExceptFeatures(ButtonStyle=ButtonStyle) {
       children(body);
       children(buttons);
     };
-    // then subtract away phone and cutouts
     union() {
+      // then the cutouts
       _PeripheralCutouts(ButtonStyle=ButtonStyle) {
         children(body);
         children(buttons);
         children(ports);
         children(camera);
       };
-      // subtract the phone
-      children(body);
-      // subtract the buttons (we want to give them a buffer)
+      // subtract the buttons (we want to give them a buffer even if ButtonStyle=extrude)
       minkowski() {
         cylinderX(r=MarginButtonsSeat, h=MarginButtonsSeat/2, center=true);
         children(buttons);
       };
-      // subtract the touchscreen area
-      translate([0, 0, tol]) _FrontCutout() children(body);
     }
   }
 }
@@ -153,14 +197,29 @@ module _Case(ButtonStyle)
 /// ```
 ///
 /// replace "Phone" above with the specific model, e.g. `PP` like `PPBody()`
-module Case(ButtonStyle="extrude") {
+module Case(ButtonStyle="extrude", RenderPhone=false) {
+  body = 0;
+  buttons = 1;
+  ports = 2;
+  camera = 3;
   // translate([PPBodyWidth + Thickness, Thickness, PPBodyHeight + Thickness])
   rotate(a=[0, 180, 0])
-  color("DarkSlateGray")
-  _Case(ButtonStyle) {
-    children(0);
-    children(1);
-    children(2);
-    children(3);
+  union() {
+    color("DarkSlateGray") _Case(ButtonStyle) {
+      children(body);
+      children(buttons);
+      children(ports);
+      children(camera);
+    };
+    if (RenderPhone) {
+      difference() {
+        union() {
+          children(body);
+          children(buttons);
+          children(camera);
+        };
+        children(ports);
+      };
+    };
   };
 }

src/cases/pp.scad

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