re-model the phone

case.scad is dead: i'll recreate it later

bits.scad

@@ -1,48 +1,60 @@
-module Volume()
+include <dimensions.scad>
+use <primitives.scad>
+
+module Volume_(Depth)
 {
-	hull() {
-		translate([10,0,0])cylinder(d=5, h=5);
-		translate([-10,0,0])cylinder(d=5, h=5);
-	}
+  cube([Depth, VolumeLength, VolumeHeight], center=false);
+}
+module Volume(Depth)
+{
+  translate([BodyWidth, VolumeMinY, VolumeMinZ])Volume_(Depth);
 }
 
-module Power()
+module Power_(Depth)
 {
-	hull() {
-		translate([5,0,0])cylinder(d=5, h=5);
-		translate([-5,0,0])cylinder(d=5, h=5);
-	}
+  cube([Depth, PowerLength, PowerHeight], center=false);
+}
+module Power(Depth)
+{
+  translate([BodyWidth, PowerMinY, PowerMinZ])Power_(Depth);
 }
 
-module Camera()
+module Camera_(Depth)
 {
-	hull() {
-		translate([0,10,0])cylinder(d=10, h=5);
-		translate([0,-10,0])cylinder(d=10, h=5);
-	}
+  cube([CameraWidth, CameraLength, Depth], center=false);
+}
+module Camera(Depth)
+{
+  translate([CameraMinX, CameraMinY, -Depth])Camera_(Depth);
 }
 
-module Speaker()
+module Usb_(Depth)
 {
-	hull() {
-		translate([0,5,0])cylinder(d=5, h=5);
-		translate([0,25,0])cylinder(d=5, h=5);
-	}
-	hull() {
-		translate([0,-5,0])cylinder(d=5, h=5);
-		translate([0,-25,0])cylinder(d=5, h=5);
-	}
+  cube([UsbWidth, Depth, UsbHeight], center=false);
+}
+module Usb(Depth)
+{
+  translate([BodyWidth/2 - UsbWidth/2, BodyLength-Depth, UsbMinZ])Usb_(Depth);
 }
 
-module Usb()
+module Aux_(Depth)
 {
-	hull() {
-		translate([0,5,0])cylinder(d=5, h=5);
-		translate([0,-5,0])cylinder(d=5, h=5);
-	}
+  translate([3.5/2, 0, 0])cylinderY(d=3.5, h=Depth);
+}
+module Aux(Depth)
+{
+  translate([AuxMinX, 0, AuxMinZ])Aux_(Depth);
 }
 
-module Microphone()
-{
-	cylinder(d=3, h=5);
-}
+// module Speaker()
+// {
+// 	hull() {
+// 		translate([0,5,0])cylinder(d=5, h=5);
+// 		translate([0,25,0])cylinder(d=5, h=5);
+// 	}
+// 	hull() {
+// 		translate([0,-5,0])cylinder(d=5, h=5);
+// 		translate([0,-25,0])cylinder(d=5, h=5);
+// 	}
+// }
+

dimensions.scad

@@ -1,5 +1,40 @@
-Length=160.5;
-Width=76.6;
-Height=9.2;
+// all measurements in mm
+//
+// x = width
+// y = length = the longest axis of the phone
+// z = height = the shortest axis of the phone
+//
+// (0, 0, 0) = top-left of the front of the phone.
+// i.e. the screen is defined to be at z=0.
 
+// phone body
+BodyLength=160.5;
+BodyWidth=76.6;
+BodyHeight=9.2;
+BodyRadXY=9.6;
+BodyRadFrontZ=1.8;
 
+// offset from top of phone to top of volume button
+VolumeMinY=26.0;
+VolumeMinZ=3.5;
+VolumeLength=19.8;
+VolumeHeight=2.0;
+
+// offset from top of phone to the top of power button
+PowerMinY=53.0;
+PowerMinZ=3.5;
+PowerLength=10.0;
+PowerHeight=2.0;
+
+// offset from left edge of phone to left edge of 3.5mm audio jack
+AuxMinX=23.0;
+AuxMinZ=4.1;
+
+UsbWidth=9.0;
+UsbHeight=3.5;
+UsbMinZ=5.1;
+
+CameraMinY=4.0;
+CameraMinX=41.6;
+CameraWidth=22.0;
+CameraLength=10.0;

phone.scad

@@ -1,26 +1,57 @@
 include <dimensions.scad>
 use <bits.scad>
+use <primitives.scad>
 
 $fs = 1;
 
-module phone (Pad=0, Bits=0)
-{
-	minkowski() {
-		cube([Length-Height+0.2, Width-Height+0.2, 0.2], true);
-		sphere(d=(Height-0.2)+Pad);
-	}
-	if(Bits != 0) {
-		// add holes for buttons and other things
-		translate([-50,Width/2+4,0]) rotate([90,0,0]) Volume();
-		translate([-25,Width/2+4,0]) rotate([90,0,0]) Power();
-		translate([-70,-17,-Height/2-4]) Camera();
-		translate([70,0,-Height/2-4]) Speaker();
-		translate([Length/2,0,0]) rotate([0,90,0]) Usb();
-		translate([Length/2,20,0]) rotate([0,90,0]) Microphone();
-	}
+Tol = 0.1;
+
+// simple box-shaped body; preserve for easier debugging
+module BodyBox() {
+  cube([BodyWidth, BodyLength, BodyHeight], center=false);
 }
 
-//%cube([Length, Width, Height], true);
-phone(Bits=1);
-%phone(4);
+// return the kernel which can be convolved with the box body to produce the actual body
+module BodyConvolve(Tol=Tol) {
+  minkowski() {
+    // cylinder rounds the four corners of the phone
+    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);
+  }
+}
 
+module Body()
+{
+  translate([BodyRadXY, BodyRadXY, BodyRadFrontZ])
+  minkowski() {
+    cube([BodyWidth-2*BodyRadXY, BodyLength-2*BodyRadXY, BodyHeight-2*BodyRadFrontZ], center=false);
+    BodyConvolve();
+  }
+}
+
+module Phone(Box=false)
+{
+  difference() {
+    union() {
+      if (Box) { BodyBox(); } else { Body(); }
+      Volume(2);
+      Power(2);
+      Camera(2);
+    }
+    union() {
+      translate([0, Tol, 0])Usb(2);
+      translate([0, -Tol, 0])Aux(2);
+    }
+  }
+}
+
+Phone();
+
+// debugging:
+// translate([0, 0, 20])Phone(Box=true);
+// translate([0, 0, 80])BodyConvolve();

primitives.scad

@@ -0,0 +1,9 @@
+/// cylinder() but with the axis on the y axis instead of the z axis
+module cylinderY(d=undef, r=undef, h=undef, center=false) {
+  rotate(a=[-90,0,0]) cylinder(d=d, r=r, h=h, center=center);
+}
+
+/// cylinder() but with the axis on the x axis instead of the z axis
+module cylinderX(d=undef, r=undef, h=undef, center=false) {
+  rotate(a=[0,-90,0]) cylinder(d=d, r=r, h=h, center=center);
+}