Fast Phone Docker

Summary

Fast docking station for a phone -- it acts as a quick charger, a stand, or even a tripod for taking photos.  It takes only one hand, and less than a second to dock or undock the phone.   

Easy to assemble, requires no external hardware, no glue, and no MMS/AMS (the model in the thumbnails is in fact printed with a single extruder).

Instructions

Using Prebuilt Models

There are prebuilt models available for several phone / case combinations.  For these, download the parts for the grip in the STL_<Phone>_<Case> folder. Print both ColorGroup1.stl and ColorGroup2.stl.   You may also need ZSpacers.stl depending on your print settings (see assembly section for details).

Stands can be found in the STL_Mounts folder.   Pick a base you like, and the back that matches the number of mounting screws for your grip.

You can also find any tools you may need in the STL_Common folder.

Using Customized Dimensions

You can create a custom model for any phone and case using OpenSCAD.  OpenSCAD is a free open-source programming language for 3d modelling. 

To use, 

1. Download the latest OpenSCAD development version -- scroll to the bottom of the page to find these

2. When you open it, go to Edit > Preferences, Select Features and ensure Roof is selected.

3. Load scad/PhoneGrip_6.0.4.scad

4. In the Window drop-down menu, ensure that Customizer is selected.   On the right you will see a Customizer pane.

5. In the customizer pane, under Part To Print ensure that Preview is selected.  Press F5 to preview -- use your mouse wheel to zoom out.   You can left-click to rotate, and right-click to drag to move. 

6. Under Phone Type select Custom and manually enter the dimensions of your phone with the case.  Most dimensions have a tolerance of +/- 2mm.   The front/back bevel and corner radius should be accurate within half a millimeter.    You can use the measuring tools in STL_Tools folder for measuring the curves and bevels.

7. Once this is done, and you're happy, go back to Part To Print and select any part you want to print.  ColorGroup1 and ColorGroup2 have all the parts required for the grip.   You'll also need to print the StandBase, and the StandBack.   Press F5 to preview each part, F6 to render, and F7 to save the STL file.

If you create one of these for a new phone/case combination, and want to share it, you can post a make, but you can also cut and paste the values from the console (near the bottom), and send it to me.   I will included it in the prebuilt values for others to use going forward.

Printing and Assembly

Printing

Print with .2mm layer height and 100% infill for all parts except for the stand.    StandBase and StandBack should be printed with less infill, and potentially higher layer height to reduce plastic usage and time.

Do not use supports -- the only piece that requires supports has them already built in.

If printing for inside of a car do not use PLA or PETG as these will warp on hot summer days

Assembly

• In the thumbnails, there is an image labeled Assembly Overview.  This can be used a a reference for how the parts fit together.

• The middle rack has some built-in supports which need to be removed post print.  Once these are removed, insert the plug brackets from the top.

• For the nuts and bolts, these may stick the first time you try to thread them, but they will loosen after being threaded once.

• If after tightening the mounting nuts, you find it starts to stick, then print the Z-Spacer parts.  These insert between the top/bottom fingers and the back plate.   These may or may not be needed depending on the compressibility of the plastic you are using, and your print settings.

• The plug will need to be adjusted as one of the last steps of assembly.   Insert your phone into the mechanism, and press the close buttons.   Insert your plug between the plug brackets and plug into the phone.  Tighten both plug screws carefully so as not to move the plug.  Open/close the mechanism a few times to ensure it doesn't catch, and that the phone takes a charge -- if it does catch, you can adjust the plug up or down by loosening the front plug screw and tightening the back, or vice versa.  If it doesn't charge, loosen the plug screws, push the plug upward into the phone and retighten

• You will need to readjust after about two weeks.  Almost all plastics shrink about 2% within a few weeks of being printed.   Simply loosen then nuts and readjust the fit when this happens.  You only need to do this once, after which the plastic stabilizes.

• Do NOT use Glue -- otherwise you will not be able to adjust it after it shrinks.   You can use glue after about a month, once the plastic has finished settling.  The only exception is for the close button caps, where you can glue right away.

Further Customization

Creating Custom Mounts

It's possible to create custom mounts, if you want to attach this to a wall, a car vent, or you just want a special purpose base.   The mechanism doesn't transfer any force to the mount, so it's possible to attach this to a car vent for example, without worry of damage.

There are two mounting systems -- one is for a three screws and the other for  four.  This is done to accommodate different camera layouts on different types of phones.   Outside of this, all generated grips will have the exact same mounting dimensions.

For the four screw system, the mounting holes are 10mm in diameter,  40mm apart in the x direction and 72mm in the y.   For the three screw it is the exact same except the top middle mount is placed halfway between where the top two mounting holes would be.

If you design a mount that requires longer mounting screws, you can use the customizer in OpenSCAD.

If you do create a custom mount, please publish it, and link it in the comments, as I'd love to see it.

Custom Decals

This model works very well with custom decals on the front plate.   It adds a bit of personalization and fun.  This can be done with or without an MMU or INDX system.   To do this:

• In Prusa Slicer (version 2.7.1 or newer), on the top right, select Expert mode

• Go to the Printers tab.   Under Capabilities, increase Extruders to 4.  Check the Single Extruder Multi Material box.   Save the printer for future use

• (suggestion:) Go to the Print settings tab  Under Wipe tower, turn the wipe tower off.

• Go back to the Plater tab. 

• On the right you'll see a list of filaments.  Click on the color box of one of them, and change to a unique color so what you do is visible.   You can also click on the gears to change the filament type, etc.

• Create or download your image as an SVG file or a flat STL file.

  • Note that you can export Template.svg from OpenSCAD, or download a template from the Template/TopPlate_<phone>.svg file of this object.  This can serve as a reference for the shape and size of the front plate 

• Go to the Add (ctrl-I), and select BOTH the STL for your main object and for your decal at the same time.   You should get a dialog box saying "multiple objects were loaded ...".   Click on yes.

  • Alternatively, load your main object, and once it's selected, right click on it, and go to Add Part, and import your decal.

• Once the decal is loaded, make sure that the height of the decal object is the same as your first layer height (or the height of the second layer which gives a cleaner look but requires an extra color change).

• On the right hand side of the screen under the objects, check that your decal is underneath the top_plate.svg object, and that its extruder number is lower than that of the top plate.    (If two objects intersect, only the lower object will be printed in the intersection.   The lower numbered extruder always prints first, which reduces artifacting)

• Slice it, and double check the bottom layer to ensure your decal is properly rendered.   Note the order that the colors print on the bottom layer, as you will have to insert the colors in that order.

When you go to print, it will now pause and start beeping when it requires a color change.   Follow the instructions on the screen.

The image on the thumbnail uses clear plastic with multiple layers.  This is considerably more complicated, and I won't go into it here, due to space.  Let me know if there's interest and I can post a tutorial on how to do this.

Share Your Builds

If you do customize this for a new phone/case, and you've verified your dimensions are correct, send me the details.   There is some text that appears near the bottom of the output in the Console pane in Openscad that will list all the relevant dimensions (look for the 'Cut Here' message).   I can upload this into the database so others can use it down the road.

If you do build this, please post a make, and be sure to leave a like, so I know this is appreciated.   Also if you have any feedback, leave a comment as I'd love to hear how this can be improved.