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Test Rigs 1

A project log for Functional Pip-Boy 3000 Mk4

Bringing a virtual device into the real world.

zapwizardzapwizard 05/04/2016 at 03:490 Comments



This post will also be my first set of video updates. I will also type out the details.
I designed a bunch of test rigs to be 3D printed on the Ultimaker 2. Each part designed to test a specific part of the design.


The first test is for the geared down radio knob, FDM 3D print was pretty rough, but did the job. The three gears mesh together and the gearing works great. There is very little to change on this area of the design.


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I printed up the communications link cable for testing. One thing I forgot was to add tolerance to the threads, and so the first print got stuck and had to be forcefully separated. Adding 0.2mm of tolerance made the parts fit together perfectly. The bayonet connection works nicely, and holds tight. Once docked it doesn't come loose until you want it. As mentioned when I designed this part, I did a reverse thread, that way if you need to somehow use more force to turn it, the black and white parts won't separate. See the video below showing how the test piece fits together.


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(Sorry about the audio on this one, next time I will use my good camera instead of my phone)




Now the cable retraction mechanism was both a success and failure.
The actual cable lock, pawl and spool all work well. I will make some changes to get the wire to wrap a bit better without jamming.


However, the spring I selected was just not designed for this type of retraction. What I need is a spiral torsion spring. However, I can't find any of these available retail, they all seem to be custom. I have a one-way retracting charger cable in my car, which I may rip apart just to see if the spring is useful, the other option is to rip apart a cheap tape measure, as they have the proper spring, although it would be far longer than I need. I will have to think about the whole mechanism a bit more. But that is what prototypes are for.

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