1-Digit Split-Flap Counter – 3D Printable Mechanical Design

@mahmoudralizadeh

Hi! To build a reliable split-flap counter with that compact 17.78 mm drum, the secret is dialing in the FDM tolerances around the 3mm shaft and flap pivots so nothing binds. I will engineer the mechanical drum, integrate the 28BYJ-48 stepper and Hall-effect sensor, and prepare all print-ready files. Quick question: Do you want the flaps designed to print flat and snap-fit into the drum, or will you be using metal pins for the hinges? With my mechanical engineering background, I specialize in designing functional, moving CAD assemblies specifically for 3D printing. Because I have hands-on prototyping experience, I understand how FDM shrinkage and layer lines affect tiny moving parts, so I build those exact clearances directly into the model. I will deliver the editable CAD, STEP, STLs, and a clear BOM so your counter works flawlessly right off the build plate.

@DavidRajaB

With my extensive experience in Mechanical Design and Product Development bolstered by a robust skill set including CAD expertise on platforms such as SolidWorks, Fusion 360 and AutoCAD, I am well-equipped to create your 1-Digit Split-Flap Counter. My work process prioritizes engineering precision and manufacturing considerations, which differentiates my deliverables as production-ready solutions. Having designed various moving mechanical parts and 3D-printable mechanisms in my career, I know the challenges involved in designing mechanisms that function properly and can be easily assembled using FDM printing. Your project requires more than a visual model - it needs a working mechanical prototype - and that is exactly what you will get with me. I will ensure that the design incorporates your provided specifications meticulously, right down to the compact drive mechanism and removable motor mount for the 28BYJ-48 stepper motor.