Rugged frame

main.scad

@@ -6,13 +6,13 @@ use <BOSL/masks.scad>
 
 // DEBUG:
 //validation = 1;
-//xray = 1;
+xray = 1;
 
 // EXPORT:
 MODEL_HARNESS_LEFT=1;
 MODEL_HARNESS_RIGHT=2;
 MODEL_HARNESS_TOP=3;
-export=2; // [0:5]
+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;
@@ -20,8 +20,13 @@ 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;
+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();
@@ -38,7 +43,7 @@ module arm() {
 module phone_harness() {
     ops=get_phone_size();
     ps=[ops.x+0.2, ops.y+0.2, ops.z+0.2];
-    w=1;
+    w=shell_wall;
     f=2;
     rf=5;
     hs=[ps.x+w*2, ps.y+w*2, ps.z+w*2];
@@ -50,10 +55,11 @@ module phone_harness() {
             cuboid(ps, fillet=f);
         }
         shell_rim();
+        shell_screwmounts();
     }
     module shell_rim() {
         $fn = $preview ? 6 : 30;
-        w=2;
+        w=shell_rim_wall;
         s=[hs.x+2*w, hs.y+2*w, 6];
         intersection() {
             difference() {
@@ -67,64 +73,99 @@ module phone_harness() {
         $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];
+        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(0.5) difference() {
+        up(0.0) difference() {
             intersection() {
                 cuboid(res, fillet=rf, edges=EDGES_Z_ALL);
-                cuboid(res, fillet=(groove?1:2), edges=EDGES_BOTTOM);
+                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, 10];
+        s=[138, 69, 100];
         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 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, 10];
+        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, 10];
-        right(ps.x/2 - top_offset) up(ps.z/2) back(23) cuboid(s, fillet=1);
+        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();
-        speaker_cutout();
+        top_speaker_cutout();
         front_camera_cutout();
         leds_cutout();
     }
     
     module back_camera_cutout() {
-        s=[13, 25, 10];
-        right(ps.x/2 - 8) fwd(ps.y/2 - 23) down(ps.z/2) cuboid(s, fillet=6, edges=EDGES_Z_ALL);
+        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=9;
-        p=[ps.x/2, ps.y/2-24, -1];
-        h=10;
-        translate(p) yrot(90) down(h/2) cylinder(h=h, d=d);
+        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=[10, 20, 6];
+        s=[100, 20, 6];
         left(ps.x/2) down(2) cuboid(s, fillet=1);
     }
     module left_cutout() {
@@ -132,7 +173,7 @@ module phone_harness() {
     }
     
     module buttons_cutout() {
-        s=[42, 10, 5];
+        s=[42, 100, 5];
         fwd(ps.y/2) right(ps.x/2 - 44.5) cuboid(s, fillet=1);
     }
     module front_cutout() {
@@ -145,9 +186,10 @@ module phone_harness() {
         left_cutout();
         right_cutout();
         front_cutout();
+        shell_screwmounts_holes();
     }
     
-    divider=[30, 0, 2.3];
+    divider=harness_divider;
     module model_harness_left() {
         intersection() {
             intersection() {