Build Instructions

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• 1

  Concept

  First, we need to plan out exactly how we’re going to pull this off.

  The ISS communicates on UHF or Ultra High Frequency bands, specifically around 437 MHz downlink.

   If you were to calculate the diameter of a dish antenna required to communicate with the ISS at these frequencies, you'd end up with something over 10 meters wide! That's clearly out of the question for a DIY project, especially one that fits on your work desk.

  
  

  So how do we create a compact antenna that can sit right on your desk? The solution is to let someone else handle the tracking and data retrieval, then feed that information into our antenna. This is much simpler and requires only a few components. For this project, you'll only need an ESP8266 microcontroller, a single RGB LED, and a few resistors to current-limit the LED.

  To get the ISS tracking data, we'll use an open-source API like Open Notify. This API continuously provides the live latitude and longitude of the ISS. With a bit of math, we can calculate the distance between your location and the ISS to determine what color the LED should display.

  
  

• 2

  CAD Designs

  For the antenna, I designed a simple model in Fusion 360 that you can easily 3D print.

  
  

  First, there are the side triangular trusses, one vertical and one inclined on each side. Next, we have the housing that neatly encloses the microcontroller and wiring. At the top, a bridge section secures the antenna dish in place, followed by the dish itself. Finally, a circular disk covers the soldered wires on the LED pins.

  
  

  Justway

  Part of this project was supported by Justway.

  Justway offers a comprehensive suite of solutions, including CNC machining, 3D printing, sheet metal fabrication, injection molding, and urethane casting, offering rapid prototyping and mass production solutions.

  
  

  Here are the steps to get your project 3D printed by Justway's 3D printing service.

  First, head over to Justway's 3D printing service and select 3D printing. You also have options like CNC machining, injection Molding and Urethane Casting. But for this project, we will use the 3D printing service.

  Click on "upload your design". A new page will appear. Here, you need to click on "Select CAD files" and upload the STL file.

  After that, select the Quantity, Material (I recommend PLA or ABS for this project). In the color section, you can either select white and paint it later, or select the color you like directly in the 3D print. This will save time later.

  Finally, after selecting all the options, you can enter your email and submit the request to get a quote.

• 3

  Assemble the Antenna

  I cut the exact shapes from the 3D model out of PVC board. I wanted to build it by hand for a more personalized feel. For the dish, I used a perfectly sized ice cream cup.

  First, I glued all the trusses together using rubber adhesive.

  
  

  Once everything looked solid, I spray-painted the structure for a nice glossy finish. You can do the same with your 3D prints if you like. 

  
  

  I painted the inside of the dish and the housing grey, which I think looks much better than plain white.

  
  

  I also glued the base to the trusses before painting. Lastly, be sure to paint the circular disc grey as well to complete the look.

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