Fitting a circuit board into a scale model is quite challenging and it usually ends up being a bespoke design. The challenge is to maximise the space within and making sure all the components fit in there. So far, in most scale models, I can skip this process because the available space was more than enough.
THE PROTON PACK IS NOT A TOY
Thanks to Adam Savage which led me to Thingiverse leading to the eventual links for the .stl files of the 1/6th scale Proton Pack. It is now possible to light them up. I have so wanted one of these ever since I saw his video years ago. Now, lighting them up is easy because of the hollow space within. Heck, even for a 1/24th scale, it is possible. Because, like any other manufacturer, all you need are some LEDs and a battery, maybe even a simple circuit board for the sequence.
But I wanted something more, which is, I wanted each pack to have its own sequence. This way, each pack more or less belongs and has that realistic feel, compared to a toy. If you had seen my design for the Spirit Pack (and if you had bought one, Thank You), you’d know each pack lights up differently, thanks to numerous rewinds on the original Movie.
THE ONE SIXTH 3D PROTON PACK
After meddling with the 3D software called FreeCAD, I got the rudimentary dimensions of the hollow space within the Proton Pack. It would be easier if I had a solid 3D printed version to confirm the measurements. And, I have created the basic PCB design from that. The only issue I have is the position of the four Cyclotron lights. There is also a small thin trench leading from the Cyclotron to the Power Cells. After measuring the opening, they are long enough to house 8 small SMD LEDs. The issue is to thread 9 thin wires to them. I would be using a microcontroller and a bank of Darlington arrays to control the LEDs. The main aim this time is to get the LED position right, then design the board and worry about the programming later. This is also the reason I placed a micro-USB onto the PCB as I intend to use ICSP programming.
THE FOOL AND HIS TOOLS
The FreeCAD software already showed me the actual position of the 4 Cyclotron windows. Positioning the LEDs to match that is not easy since I do not know how to align both files digitally. Therefore, I went back to my most foolproof and ‘traditional’ method since I’m a fool. The basic concept is simple: you place a sheet of tracing paper over the drawing and draw over it.
Using the same method, I would have to position the software layer I am working on, on top of an original source. Sometimes, it involves keybpard-flipping the two software over and over again. This time, because it is a circle housed within a square, I would match the two drawings as best as I can, and then minimising one of the windows. This can be done on any layer since I have already picked the component and hover-positioned it with the mouse. You can do it in any combination as long as you get the two to match exactly, or above 90% accuracy.
For me, this as close as I can get without a physical model. I am not too worried about it since I can use some a red diffused transparent sheet and move the board back a little. That is my saving ‘margin of error’. Anyway, I have sent the design out twice, with the first being rushed out, I completely forgot to look into the switches. Once they come back, I hope to get some 3D prints in my hands so I can see for myself if the board measurements are correct.
Where to get what:
The 1/6th Proton Pack from TheNewHobbyist as used by Adam Savage
The Remixed Version of the above for Lighting by biho1
The simplified GB Wand by roadie3rd (but needs scaling to 8cm and has extended barrel)
