3D Mouse With 3D Printed Flexures And PCB Coils

January 31, 2024 by Danie Conradie 7 Comments

3D mice with six degrees of freedom (6DOF) motion are highly valued by professional CAD users. However, the entry-level versions typically cost upwards of $150 and are produced by a single manufacturer. [Colton Baldridge] has created the OS3M Mouse — an open source alternative using PCB coils and 3D printed flexures.

The primary challenges in creating a 6DOF input device, similar to the 3Dconnexion Space Mouse, lie in developing a mechanical coupling that enables full range motion, and electronics capable of precisely and consistently measuring this motion. After several iterations of printed flexure combinations and trip down the finite element analysis (FEA) rabbit hole, [Colton] had a working single-piece mechanical solution.

To measure the knob’s movement accurately, [Colton] employs inductive sensing. Inductance to Digital Converters (LDCs) assess the inductive alterations across three pairs of PCB coils, each having an opposing metal disk mounted on the knob. This setup allows [Colton] to use a Stewart platform‘s kinematic model calculate the knob’s relative position. The calculation are done on an STM32 which also acts USB HID send the position data to a computer. For the demo [Colton] created a simple C++ app to translate the position data to Solidworks API calls.

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A Spinning Egg For Your Thoughts

October 1, 2023 by Danie Conradie 15 Comments

Brushless motors are fascinating devices that come in all sorts of shapes and sizes, but you’ve probably never seen one in the form of a free-spinning shiny metal egg. Created by [David Windestål], [Giacomo Di Muro], and [Chad Kapper], the Motion Zero is part top, part brushless motor, and fully mesmerizing. Tech overview video after the break.

Like the classic Tippe Top toy, an ovoid shape like this shiny metal egg will stand on its end if it’s spun fast enough. To do this, the team embedded magnets in the metal egg, effectively turning it into a rotor. An array of 4 PCB coils under a smooth concave surface serves as the stator. Because the egg is not held in position by a shaft, hall effect sensors were incorporated to determine the position of the egg, and properly control the state of the coils to keep it spinning.

Recognizing how easy it was to get lost in thought while staring at a shiny spinning egg, the rest of the device was designed with meditation in mind. The top cover is a block of aluminum machined with ripple patterns, with ball bearings that slide between the ripples as the control interface. Additional hall effect sensors on the PCB determine the position of the balls to adjust the rotation speed and shut-off timer. You can even choose to make the egg move around or remain in one position. The main controller is an ESP32 module, which reads all the hall effect sensors and controls the coils via motor drivers.

The Motion Zero has made its debut on Kickstarter and already exceeded its initial funding goal. We like the creators’ willingness to share the inner workings of a product that manages to transform a simple concept into a mesmerizing piece of engineering artistry.

We’ve seen a good bit of [David Windestål]’s has a fascination with weird tech over the years, like racing belt sanders, fire breathing waterfowl, tri and bicopters. He even built a prop anti-drone RF cannon for a movie.

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A display based on magnetic viewing film

Moving Magnet Draws Stylish Shapes On Flexible Film

March 8, 2023 by Robin Kearey 2 Comments

[Moritz v. Sivers] has a knack for making his own displays, which are typically based on some obscure physical effect. Magnetic viewing films, those thin plastic sheets that change color in response to a magnetic field, are his latest area of interest, as you can see in his Magnetic Kinetic Art Display.

The overall idea of the display is similar to a kinetic sand art table, in which a ball traces out shapes in a pile of sand. In [Moritz]’s project, the magnetic viewing film is the sand, and a 2 mm diameter magnet is the ball. The magnet is moved along the film by two sets of coils embedded inside a flex PCB mounted just below the film. One set of coils, on the top layer of the PCB, moves the magnet in the x direction, while a second set on the bottom layer moves it in the y direction.

A flex PCB with coils on both sides — The flex PCB is small, but carries lots of windings

[Moritz] used a flex PCB not because it had to be bendy, but to keep the two sets of coils as close together in the z direction as possible. This helps to avoid a big difference in strength between the two directions. To drive the coils, he used a pair of TB6612FNG stepper motor drivers, controlled by a Wemos D1 Mini.

The housing was 3D printed mostly from PLA, but with a few bits done in PETG. This was for structural rigidity as well as thermal performance — the coils can carry up to two amps and get pretty warm as a result.

The video, embedded below, shows some of the shapes that can be drawn: squares, spirals and even digits to turn the display into a clock. [Moritz] got the PCB coil idea from a project by [bobricius], and cleverly extended it into a useful product. It’s not the first time [Moritz] used magnetic viewing film to make a clock, either.

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Mechanical Seven-Segment Display, Smaller And Better Than The Original

February 4, 2021 by Dan Maloney 19 Comments

One thing we love here at Hackaday is when we get to track the evolution of a project over time. Seeing a project grow over time is pretty typical — scope creep is real, after all. But watching a project shrink can be a real treat too, as early versions get refined into sleeker and more elegant solutions.

This slimmed-down mechanical seven-segment display is a perfect example of that downsizing trend. When we saw [IndoorGeek]’s first vision of an electromechanical display, it was pretty chunky. Then as now, each segment is a 3D-printed piece with a magnet attached to the rear. The segments hover over solenoid coils, which when energized repel the magnet and protrude the segment, forming the desired digit. The old version used large, hand-wound coils, though, making the display pretty bulky front to back.

Version 2 of the display takes a page from [Carl Bugeja]’s playbook and replaces the wound coils with PCB coils. We’ve seen [Carl]’s coils on both rigid substrates and flex PCBs; [IndoorGeek] used plain old FR4 here. The coils occupy four layers so they have enough oomph to extend and retract each segment, and the PCB includes space for H-bridge drivers for each segment. The PCB forms the rear cover for the display, which is also considerably slimmed down for this version. What’s the same, though, is how good this display looks, especially with strong side-lighting — the shadows cast by the extended segments are striking against the plain white face of the display.

Congratulations to [IndoorGeek] on a great-looking build and a useful improvement over the original.

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Jigsaw Motor Uses PCB Coils For Radial Flux

July 16, 2019 by Dan Maloney 7 Comments

Electric motors are easy to make; remember those experiments with wire-wrapped nails? But what’s easy to make is often hard to engineer, and making a motor that’s small, light, and powerful can be difficult. [Carl Bugeja] however is not one to back down from a challenge, and his tiny “jigsaw” PCB motor is the latest result of his motor-building experiments.

We’re used to seeing brushless PCB motors from [Carl], but mainly of the axial-flux variety, wherein the stator coils are arranged so their magnetic lines of force are parallel to the motor’s shaft – his tiny PCB motors are a great example of this geometry. While those can be completely printed, they’re far from optimal. So, [Carl] started looking at ways to make a radial-flux PCB motor. His design has six six-layer PCB coils soldered perpendicular to a hexagonal end plate. The end plate has traces to connect the coils in a star configuration, and together with a matching top plate, they provide support for tiny bearings. The rotor meanwhile is a 3D-printed cube with press-fit neodymium magnets. Check out the build in the video below.

Connected to an ESC, the motor works decently, but not spectacularly. [Carl] admits that more tweaking is in order, and we have little doubt he’ll keep optimizing the design. We like the look of this, and we’re keen to see it improved.

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