3D-Printable Dead-Man PWM Control

I need a compact hand-held controller that combines a dead-man safety switch with a rotary potentiometer and feeds a clean PWM signal into an Arduino-based drive system for an axial flux motor traction inverter. When the side button is depressed, the rotary pot should dictate motor speed; the instant the button is released the output must drop to the same state as an e-stop, guaranteeing zero drive. The housing has to be fully 3D printable on a typical FDM printer (200 × 200 × 200 mm envelope, PLA or PET-G). Ergonomics matter—I’m picturing something that can be gripped like a bicycle throttle with the thumb naturally resting on the kill switch—but feel free to propose alternatives if they remain compact and printable without supports in awkward internal cavities. I’m an advanced Arduino user, so focus on solid electronics and mechanical design rather than step-by-step tutorials. I still expect well-commented code and clearly labeled schematics so I can integrate the unit straight into my existing control stack. Deliverables • STP/STEP and STL files for all printable parts, oriented for reliable printing • Complete wiring diagram and parts list (switch, rotary pot, debounce or filter components, suggested Hall effect alternative if you see fit) • Arduino sketch that reads the pot, debounces the switch, and outputs a 2–20 kHz PWM with adjustable min/max duty cycle parameters • Brief testing procedure showing the signal goes low the moment the button is released and resumes instantly when pressed If you’ve built similar safety throttles or can show strong mechanical design chops, that’s a big plus. Looking forward to seeing your approach.

Project ID: 40418841