Add backplane and rails with sliders

3 years ago · c259f393e3
--- a/main.scad
+++ b/main.scad
@@ -3,6 +3,7 @@ include <BOSL/constants.scad>
 use <BOSL/transforms.scad>
 use <BOSL/shapes.scad>
 use <BOSL/masks.scad>
 use <BOSL/sliders.scad>

 // DEBUG:
 //validation = 1;
@@ -12,6 +13,8 @@ use <BOSL/masks.scad>
 MODEL_HARNESS_LEFT=1;
 MODEL_HARNESS_RIGHT=2;
 MODEL_HARNESS_TOP=3;
 MODEL_HARNESS_SLIDER_FRONT=4;
 MODEL_HARNESS_SLIDER_BACK=5;
 export=0; // [0:5]
 function is_not_export() = is_undef(export) || export == 0;
 function is_export() = !is_not_export();
@@ -20,14 +23,6 @@ function is_model(m) = is_not_export() || export == m;

 function get_phone_size() = [160, 76.7, 10];

 shell_wall=3;
 shell_rim_wall=3;
 rim_edge_thickness=1.2;
 rim_edge_tolerance=0.4;
 expose_back_camera=false;
 screwmount_screw=3;
 harness_divider=[30, 0, 1.3];

 module phone() {
    s=get_phone_size();
    color("gray")
@@ -43,10 +38,23 @@ module arm() {
 module phone_harness() {
    ops=get_phone_size();
    ps=[ops.x+0.2, ops.y+0.2, ops.z+0.2];
    shell_wall=3;
    shell_rim_wall=3;
    rim_edge_thickness=1.2;
    rim_edge_tolerance=0.4;
    expose_back_camera=false;
    screwmount_screw=3;
    harness_divider=[16, 0, 1.3];
    harness_size=[ps.x+shell_wall*2, ps.y+shell_wall*2, ps.z+shell_wall*2];
    rim_size=[harness_size.x+2*shell_rim_wall, harness_size.y+2*shell_rim_wall, 6];
    
    w=shell_wall;
    f=2;
    rf=5;
    hs=[ps.x+w*2, ps.y+w*2, ps.z+w*2];
    hs=harness_size;
    backplane_rim_size=[30, ps.y*0.95, shell_wall/2];
    
    // ==== SHELL ====
    
    module shell() {
        $fn = $preview ? 6 : 30;
@@ -60,7 +68,7 @@ module phone_harness() {
    module shell_rim() {
        $fn = $preview ? 6 : 30;
        w=shell_rim_wall;
        s=[hs.x+2*w, hs.y+2*w, 6];
        s=rim_size;
        intersection() {
            difference() {
                cuboid(s, fillet=rf, edges=EDGES_Z_ALL);
@@ -68,6 +76,9 @@ module phone_harness() {
            }
            cuboid(s, fillet=1);
        }
        rail_extension=10;
        fwd(hs.y/2) xrot(90) harness_rail(slider_len_front+rail_extension);
        back(hs.y/2) xrot(-90) harness_rail(slider_len_back+rail_extension);
    }
    module shell_rim_edge(thickness, groove, tolerance=rim_edge_tolerance) {
        $fn = $preview ? 6 : 30;
@@ -103,7 +114,38 @@ module phone_harness() {
            up(hs.z-1) cylinder(d=screwmount_screw+1.5, h=5);
        }
    }
    module shell_backplane(groove) {
        down(hs.z/2 - shell_wall/6) up(backplane_rim_size.z/2) right(harness_divider.x) scale(groove ? 1.01 : 1) cuboid(backplane_rim_size, fillet=5, edges=EDGES_Z_LF);
    }
    
    // ==== SHELL SLIDER AND RAIL ====
    
    rail_angle=36;
    rail_wall=1;
    slider_slop=0.1;
    slider_len_back=hs.x*0.3;
    slider_len_front=hs.x*0.3;
    module harness_slider(l) {
        base=2;
        ss=[l, shell_rim_wall, rim_size.z+rail_wall*2];
        up(ss.y + base) xrot(180) slider(l=ss.x, w=ss.z, h=ss.y, base=base, chamfer=0.9, wall=2, ang=rail_angle, slop=slider_slop, orient=ORIENT_X, align=V_UP);
    }
    module harness_rail(l) {
        sw=2;
        ss=[l, shell_rim_wall, rim_size.z+rail_wall*2];
        rail(l=ss.x, w=ss.z, h=ss.y, chamfer=0.5, ang=rail_angle, orient=ORIENT_X, align=V_UP);
    }
    
    // ==== SHELL CUTOUTS ====
    module shell_cutouts() {
        top_cutout();
        bottom_cutout();
        left_cutout();
        right_cutout();
        front_cutout();
        shell_screwmounts_holes();
    }
    // -- TOP --
    module screen_cutout() {
        s=[138, 69, 100];
        up(s.z/2) cuboid(s, fillet=3, edges=EDGES_Z_ALL);
@@ -130,6 +172,7 @@ module phone_harness() {
        leds_cutout();
    }
    
    // -- BOTTOM --
    module back_camera_cutout() {
        s=[13, 25, expose_back_camera ? 100 : 11];
        right(ps.x/2 - 7.5) fwd(ps.y/2 - 23) down(s.z/2 - ps.z/3) cuboid(s, fillet=6, edges=EDGES_Z_ALL);
@@ -153,6 +196,7 @@ module phone_harness() {
        bottom_speaker_cutout();
    }
    
    // -- RIGHT --
    module headphones_cutout() {
        $fn = $preview ? 10 : 30;
        d=8.8;
@@ -164,6 +208,7 @@ module phone_harness() {
        headphones_cutout();
    }
    
    // -- LEFT --
    module usbc_cutout() {
        s=[100, 20, 6];
        left(ps.x/2) down(2) cuboid(s, fillet=1);
@@ -172,6 +217,7 @@ module phone_harness() {
        usbc_cutout();
    }
    
    // -- FRONT --
    module buttons_cutout() {
        s=[42, 100, 5];
        fwd(ps.y/2) right(ps.x/2 - 44.5) cuboid(s, fillet=1);
@@ -180,14 +226,7 @@ module phone_harness() {
        buttons_cutout();
    }
    
    module shell_cutouts() {
        top_cutout();
        bottom_cutout();
        left_cutout();
        right_cutout();
        front_cutout();
        shell_screwmounts_holes();
    }
    // ==== MODEL ====
    
    divider=harness_divider;
    module model_harness_left() {
@@ -200,6 +239,7 @@ module phone_harness() {
                shell();
                shell_rim_edge(rim_edge_thickness, groove=true, tolerance=rim_edge_tolerance);
                shell_cutouts();
                shell_backplane(groove=true);
            }
        }
    }
@@ -215,6 +255,7 @@ module phone_harness() {
                shell_cutouts();
            }
        }
        shell_backplane(groove=false);
    }
    module model_harness_top() {
        intersection() {
@@ -229,10 +270,21 @@ module phone_harness() {
            shell_cutouts();
        }
    }
    module model_harness_slider_front() {
        difference() {
            fwd(hs.y/2) xrot(90) harness_slider(slider_len_front);
            front_cutout();
        }
    }
    module model_harness_slider_back() {
        back(hs.y/2) xrot(-90) harness_slider(slider_len_back);
    }
    
    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();
    if (is_model(MODEL_HARNESS_SLIDER_FRONT)) model_harness_slider_front();
    if (is_model(MODEL_HARNESS_SLIDER_BACK)) model_harness_slider_back();
 }

 module model() {