Sorter Uses Cardboard to Organize Card Hoard

If you collect trading cards of any kind, you know that storage quickly becomes an issue. Just ask [theguymasamato]. He used to be really into trading cards, and got back into it when his kids caught the bug. Now he’s sitting on 10,000+ cards that are largely unorganized except for a few that made it into sleeve pages.  They tried to go through them by hand, but only ended up frustrated and overwhelmed. Then he found out about [Michael Portera]’s Pi-powered LEGO card sorter and got all fired up to build a three-part system that feeds cards in one by one, scans them, and sorts them into one of 22 meticulously-constructed cardboard boxes.

[theguymasamato]’s card sorter is the last stop for a card after the feeder has fed it in from the pile and the scanner has scanned it. The sorter lazy Susans around on a thrust bearing, which is driven by a 3D printed drive wheel attached to a stepper. The stepper is controlled with an Arduino.

Here’s where it gets crazy: the drive wheel and timing belt are made from the flutes of corrugated cardboard. As in, he used that wavy bit in the middle as gear teeth. Every one of those cardboard teeth is fortified with wood glue, a time-consuming process he vows to never repeat. Instead, [theguymasamato] recommends using shims to shore them up as he did in the card feeder. The whole thing was originally going to be made from cardboard. It proved to be too mushy to support the thrust bearing, so [theguymasamato] switched to MDF.

Right now, the sorter is homed via button press, but future plans for the device include an IR break beam switch. We’re excited for the scanner and can’t wait to see the whole system put together. While [theguymasamato] works on that, position yourself past the break to watch the build video.

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