Split Flap Assembly and Design
Introduction: Split Flap Assembly and Design
Welcome to our Split Flap Assembly and Design Instructable! Split flap displays are a fun, and quirky way to display messages in alphanumeric text. Since the instructions here are pretty lengthy, we've grouped the steps into 4 major categories:
1. Electrical Assembly
2. Hardware Engineering
3. Character Lettering Design
4. Software Programming
Supplies
Materials for the Electrical Assembly (per split-flap unit):
1x Arduino nano (every) 1 https://www.amazon.com/dp/B07VX7MX27
1x Perfboard 24x18 holes (5x7cm) https://www.amazon.com/dp/B07LF78ZY3
1x Stepper motor Nema 17 with step angle 1.8deg https://www.amazon.com/dp/B094CQ4DBQ
1x A4988 Stepper Motor Driver with Heat Sink https://www.amazon.com/dp/B07BND65C8
1x Male header pins 4-pin https://www.amazon.com/dp/B0774VBJ3J
2x Female header pins 15-pin
2x Female header pins 8-pin
2x Female header pins 3-pin
2x Female header pins 2-pin
3x Female header pins 1-pin
1x Hall Effect Sensor https://www.amazon.com/dp/B07QS6PN3B
3x colors 22AWG Solid Core Wire https://www.amazon.com/dp/B07TX6BX47
4x TOTAL (for up to 8 split-flaps) Wire Nuts https://www.amazon.com/dp/B01MPXUEPO
2x TOTAL (for up to 8 split-flaps) 5KOhm resistors https://www.amazon.com/dp/B07HDFN3NV
Materials for Hardware Design (per split-flap unit):
2x Wooden Housing Case
1x Front Acrylic Panel
1x Acrylic Laser Cut Side Panel
1x Acrylic Laser Cut Right Wheel
1x Acrylic Laser Cut Left Wheel
1x 3D Printed Hub
1x 3D Printed Motor Mount
50x Split Flap
1x Acrylic Spring Holder
1x Aluminum Spring Holder
1x Spring Tin Strip
1x Motor Coupling + its screws
1x Magnet (for hall effect sensor)
4x #4 Washer
4x 4-40 Nut
4x 4-40 Bolt
11x #4 Wood Screws
4x 2/56 Nut
2x 4-40 Nut
2x #4 Washer
2x 4-40 x 1/2” screw
2x 4-40 x 3/8” screw
4x 2/56 x 3/8 Screws
4x 8mm M3 Screw
Materials for Character-Lettering Design
2x sheets of vinyl per 50-flap split-flap in the colors that you want the lettering to appear in
1x Silhouette Cameo
1x cutting mat
Step 1: Electrical Assembly - Supplies
Here is an image containing all the supplies you will need to assemble the electrical wiring. 16
See the supplies section above for a comprehensive list of all the needed components and links to purchase each
Step 2: Electrical Assembly 1
The diagram is what we will be building today. Feel free to build it your own way or follow our detailed instructions below!
First, solder wires to the hall effect sensor. Make sure the sensor is flipped the right way (when the face with chamfered edges is facing you, the wires are power, ground and signal left to right)! Add heat shrink for insulating the wires.
Step 3: Electrical Assembly 2
Cut the header pins down to the following lengths:
1x male 4-pin
2x female 15-pin
2x female 8-pin
2x female 3-pin
2x female 2-pin
3x female 1-pin
Step 4: Electrical Assembly 3
Place and solder components to perf board according to our design here. Your perf board's coordinates might not exactly match our spreadsheet, so be sure to still count the coordinates!
(For assembly, use the Top View; for soldering, use Bottom View, flipping around a left-right axis)
1. Plug 2 female 8-pin into the driver
2. Plug 2 female 15-pin into Arduino
3. Put Arduino onto the board and solder the pins to the board (Bottom View, solder D2-16, J2-16)
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