PinePhoneBoy/main.scad

// 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];

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")
    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=shell_wall;
    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();
        shell_screwmounts();
    }
    module shell_rim() {
        $fn = $preview ? 6 : 30;
        w=shell_rim_wall;
        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), 3];
        resi=[hs.x+2*offset, hs.y+2*offset, res.z+1];
        up(0.0) difference() {
            intersection() {
                cuboid(res, fillet=rf, edges=EDGES_Z_ALL);
                cuboid(res, fillet=(groove?1:1.5), edges=EDGES_BOTTOM);
            }
            cuboid(resi, fillet=rf, edges=EDGES_Z_ALL);
        }
    }
    module foreach_screwmount() {
        for(x = [0:1]) for (y = [0:1]) {
            translate([(-0.5+x)*ps.x, (-0.5+y)*ps.y, -hs.z/2])
            children();
        }
    }
    module shell_screwmounts() {
        $fn = $preview ? 6 : 30;
        r=3;
        foreach_screwmount() {
            cylinder(r=r, h=hs.z);
        }
    }
    module shell_screwmounts_holes() {
        $fn = $preview ? 6 : 30;
        foreach_screwmount() {
            up(w) cylinder(d2=screwmount_screw, d1=screwmount_screw*0.5, h=hs.z+1);
            up(hs.z-1) cylinder(d=screwmount_screw+1.5, h=5);
        }
    }
    
    module screen_cutout() {
        s=[138, 69, 100];
        up(s.z/2) cuboid(s, fillet=3, edges=EDGES_Z_ALL);
    }
    top_offset=6.5;
    module top_speaker_cutout() {
        s=[3, 12, 100];
        right(ps.x/2 - top_offset) up(s.z/2 - ps.z/3) cuboid(s, fillet=1);
    }
    module front_camera_cutout() {
        $fn = $preview ? 6 : 30;
        d=5;
        s=[d, d, 100];
        right(ps.x/2 - top_offset) fwd(11) cylinder(d=s.x, h=s.z);
    }
    module leds_cutout() {
        s=[4, 14, 100];
        right(ps.x/2 - top_offset) up(s.z/2 - ps.z/3) back(23) cuboid(s, fillet=1);
    }
    module top_cutout() {
        screen_cutout();
        top_speaker_cutout();
        front_camera_cutout();
        leds_cutout();
    }
    
    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);
    }
    module bottom_speaker_cutout() {
        s=[8, 49, 100];
        left(ps.x/2 - 13)
        difference() {
            down(s.z/2 - ps.z/3) cuboid(s, fillet=1);
            bars=8;
            down(ps.z/2)
            for (i = [0:bars-1]) {
                bs=[s.x+2, 1, 2];
                step=s.y/bars;
                fwd(i*step - s.y/2 + step/2) down(w) cube(bs, center=true);
            }
        }
    }
    module bottom_cutout() {
        back_camera_cutout();
        bottom_speaker_cutout();
    }
    
    module headphones_cutout() {
        $fn = $preview ? 10 : 30;
        d=8.8;
        p=[ps.x/2, ps.y/2-24, -0.88];
        h=100;
        translate(p) yrot(90) down(10) cylinder(h=h, d=d);
    }
    module right_cutout() {
        headphones_cutout();
    }
    
    module usbc_cutout() {
        s=[100, 20, 6];
        left(ps.x/2) down(2) cuboid(s, fillet=1);
    }
    module left_cutout() {
        usbc_cutout();
    }
    
    module buttons_cutout() {
        s=[42, 100, 5];
        fwd(ps.y/2) right(ps.x/2 - 44.5) cuboid(s, fillet=1);
    }
    module front_cutout() {
        buttons_cutout();
    }
    
    module shell_cutouts() {
        top_cutout();
        bottom_cutout();
        left_cutout();
        right_cutout();
        front_cutout();
        shell_screwmounts_holes();
    }
    
    divider=harness_divider;
    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();
        }
    }
}