Element G

3D Print the overlay shell

• We will use the workshop’s Ultimaker 3 or s5 3D printer and print the overlay shell white Polymaker PLA. It will be printed at the speed of 65-75 mm/s, with a brim for better adhesion, a .16 mm layer height, a nozzle temperature of 210o C, and a print bed temperature of 65o C. Due to the carefully designed element, minimal supports will be required. Supports will only be needed to support the parts of the battery compartment and button mount.

3D Print the inside hardware separation shelf, manual toggle button, battery door, along with slider mechanism arms and slider cover.

• We will use the workshop’s Ultimaker 3 or s5 printer and print the hardware shelf, button, and slider mechanism and its cover white Polymaker PLA. It will be printed at the speed of 65-75 mm/s, with a brim for better adhesion, a .16 mm layer height, a nozzle temperature of 210o C, and a print bed temperature of 65o C. Supports will only be needed on part of the hardware separation shelf; all other components in this section are not planned to have supports.

Construct the circuit

• We will wire our circuit that consists of a servo motor, Arduino nano, 9V battery, PIR sensor, button, and soldered breadboard.

Code the circuit

• We will code the circuit to be able to flip the switch if motion is detected by the PIR sensor or when a button is manually pressed to toggle the switch

Test the circuit

• Test reliability of the servo, sensor, and button to ensure functionality when installed.

Install the circuit into the 3D-printed overlay shell

• Using the 3D-printed hardware separation shelf, along with mounts placed directly on the overlay shell, we will mount the constructed circuit hardware to the module, all except for the battery.

Install the 3D Printed battery door using screws.

Install the 3D-printed hardware separation shelf and slider mechanism inside the 3D-printed overlay shell.

• We will insert the hardware shelf, with all the components attached, and then insert and bolt together the slide mechanism, mounting it to the servo.

Install 3D printed slider cover overtop of slider arm to secure slider at all times.

Screw the back plate on using screws and modeled holes

Place sticky adhesive strips on the back of the shell

Installation

• After purchasing the product, open the compartment on the bottom by unscrewing the hatch. Next, place a 9V battery into the compartment, attaching it to the battery connector. Then, make sure your light switch is up and simply peel the paper tabs off of the back of the sticky adhesion, previously placed on the back of the product. Then, put the overlay over the desired light switch with the sticky tabs toward the wall and push for 15 seconds. Check if the product is stably mounted and the mechanism is able to flip the switch (test by clicking the manual toggle button located on the front face of the product). If the mechanism is unable to hit the switch correctly, adjust the position ensuring the two prongs on the back side can make contact with the light switch. Repeat until effective.

Use

• The device is autonomous so there is little user interaction required. Just walk in and out of the room and watch the light turn on and off. If desired, you can manually toggle your lights by pressing the button on the front-facing side of the cover.

Maintenance

• To change the battery, simply unscrew the battery compartment located on the bottom of the overlay. Switch out the 9V battery and place the battery compartment cover back on, screwing it tight with the screw. If needed, remove the entire system from the wall and complete this step. Afterward, remount the system using the adhesion and the same steps as mentioned above.