Base phone harness

main.scad

@@ -0,0 +1,218 @@
+// dependency: https://github.com/revarbat/BOSL
+include <BOSL/constants.scad>
+use <BOSL/transforms.scad>
+use <BOSL/shapes.scad>
+use <BOSL/masks.scad>
+
+// DEBUG:
+//validation = 1;
+//xray = 1;
+
+// EXPORT:
+MODEL_HARNESS_LEFT=1;
+MODEL_HARNESS_RIGHT=2;
+MODEL_HARNESS_TOP=3;
+export=0; // [0:5]
+function is_not_export() = is_undef(export) || export == 0;
+function is_export() = !is_not_export();
+function is_model_strict(m) = is_export() && export == m;
+function is_model(m) = is_not_export() || export == m;
+
+function get_phone_size() = [160, 76.7, 10];
+
+rim_edge_thickness=0.8;
+rim_edge_tolerance=0.6;
+
+module phone() {
+    s=get_phone_size();
+    color("gray")
+    cuboid(s, fillet=5);
+}
+module arm() {
+    $fn=6;
+    s=[210, 55, 50];
+    color("SaddleBrown")
+    down(s.z/2 + get_phone_size().z/2) cuboid(s, fillet=20);
+}
+
+module phone_harness() {
+    ops=get_phone_size();
+    ps=[ops.x+0.2, ops.y+0.2, ops.z+0.2];
+    w=1;
+    f=2;
+    rf=5;
+    hs=[ps.x+w*2, ps.y+w*2, ps.z+w*2];
+    
+    module shell() {
+        $fn = $preview ? 6 : 30;
+        difference() {
+            cuboid(hs, fillet=f);
+            cuboid(ps, fillet=f);
+        }
+        shell_rim();
+    }
+    module shell_rim() {
+        $fn = $preview ? 6 : 30;
+        w=2;
+        s=[hs.x+2*w, hs.y+2*w, 6];
+        intersection() {
+            difference() {
+                cuboid(s, fillet=rf, edges=EDGES_Z_ALL);
+                cuboid(ps, fillet=f, edges=EDGES_Z_ALL);
+            }
+            cuboid(s, fillet=1);
+        }
+    }
+    module shell_rim_edge(thickness, groove, tolerance=rim_edge_tolerance) {
+        $fn = $preview ? 6 : 30;
+        w=thickness + (groove ? tolerance : 0);
+        offset=(groove ? 0 : tolerance/2);
+        res=[hs.x+2*(w+offset), hs.y+2*(w+offset), 4.5];
+        resi=[hs.x+2*offset, hs.y+2*offset, res.z+1];
+        up(0.5) difference() {
+            intersection() {
+                cuboid(res, fillet=rf, edges=EDGES_Z_ALL);
+                cuboid(res, fillet=(groove?1:2), edges=EDGES_BOTTOM);
+            }
+            cuboid(resi, fillet=rf, edges=EDGES_Z_ALL);
+        }
+    }
+    
+    module screen_cutout() {
+        s=[138, 69, 10];
+        up(s.z/2) cuboid(s, fillet=3, edges=EDGES_Z_ALL);
+    }
+    top_offset=6.5;
+    module speaker_cutout() {
+        s=[3, 12, 10];
+        right(ps.x/2 - top_offset) up(ps.z/2) cuboid(s, fillet=1);
+    }
+    module front_camera_cutout() {
+        $fn = $preview ? 6 : 30;
+        d=5;
+        s=[d, d, 10];
+        right(ps.x/2 - top_offset) fwd(11) cylinder(d=s.x, h=s.z);
+    }
+    module leds_cutout() {
+        s=[4, 14, 10];
+        right(ps.x/2 - top_offset) up(ps.z/2) back(23) cuboid(s, fillet=1);
+    }
+    module top_cutout() {
+        screen_cutout();
+        speaker_cutout();
+        front_camera_cutout();
+        leds_cutout();
+    }
+    
+    module back_camera_cutout() {
+        s=[13, 25, 10];
+        right(ps.x/2 - 8) fwd(ps.y/2 - 24) down(ps.z/2) cuboid(s, fillet=6, edges=EDGES_Z_ALL);
+    }
+    module bottom_cutout() {
+        back_camera_cutout();
+    }
+    
+    module headphones_cutout() {
+        $fn = $preview ? 10 : 30;
+        d=9;
+        p=[ps.x/2, ps.y/2-24, -1];
+        h=10;
+        translate(p) yrot(90) down(h/2) cylinder(h=h, d=d);
+    }
+    module right_cutout() {
+        headphones_cutout();
+    }
+    
+    module usbc_cutout() {
+        s=[10, 20, 8];
+        left(ps.x/2) down(1) cuboid(s, fillet=1);
+    }
+    module left_cutout() {
+        usbc_cutout();
+    }
+    
+    module buttons_cutout() {
+        s=[42, 10, 5];
+        fwd(ps.y/2) right(ps.x/2 - 42) cuboid(s, fillet=1);
+    }
+    module front_cutout() {
+        buttons_cutout();
+    }
+    
+    module shell_cutouts() {
+        top_cutout();
+        bottom_cutout();
+        left_cutout();
+        right_cutout();
+        front_cutout();
+    }
+    
+    divider=[30, 0, 2.3];
+    module model_harness_left() {
+        intersection() {
+            intersection() {
+                translate(divider) downcube([1000, 1000, 1000]);
+                translate(divider) leftcube([1000, 1000, 1000]);
+            }
+            difference() {
+                shell();
+                shell_rim_edge(rim_edge_thickness, groove=true, tolerance=rim_edge_tolerance);
+                shell_cutouts();
+            }
+        }
+    }
+    module model_harness_right() {
+        intersection() {
+            intersection() {
+                translate(divider) downcube([1000, 1000, 1000]);
+                translate(divider) rightcube([1000, 1000, 1000]);
+            }
+            difference() {
+                shell();
+                shell_rim_edge(rim_edge_thickness, groove=true, tolerance=rim_edge_tolerance);
+                shell_cutouts();
+            }
+        }
+    }
+    module model_harness_top() {
+        intersection() {
+            translate(divider) upcube([1000, 1000, 1000]);
+            difference() {
+                shell();
+                shell_cutouts();
+            }
+        }
+        difference() {
+            shell_rim_edge(rim_edge_thickness, groove=false);
+            shell_cutouts();
+        }
+    }
+    
+    if (is_model(MODEL_HARNESS_LEFT)) model_harness_left();
+    if (is_model(MODEL_HARNESS_RIGHT)) model_harness_right();    
+    if (is_model(MODEL_HARNESS_TOP)) model_harness_top();
+}
+
+module model() {
+    phone_harness();
+}
+
+if (!is_undef(validation)) {
+    intersection() {
+        phone();
+        model();
+    }
+} else {
+    intersection() {
+        if (!is_undef(xray)) {
+            span_cube([0,1000*xray], [0,1000*xray], [-1000,1000]);
+        }
+        union() {
+            if (is_not_export()) {
+                //phone();
+                //arm();
+            }
+            model();
+        }
+    }
+}