CAD Assembly
The following mechanical features make up the game:
1) Rotating obstacle course
2) The conductor rack-and-pinion
3) Gear dispensing system
4) Housing for electronic and mechanical elements
5) Laser cut and 3D printed decorations
Details on each of these features are listed below.
8 obstacles are rigidly attached to a threaded rod rotating within brass bushings that are constrained translationally by slots on the top and bottom of the mechanism. A timing belt-pulley system transfers rotational motion from the servo to the obstacle's central drum, rotating both the top and bottom obstacles together at the player's desired speed. Timing belt not pictured in CAD.
Moving Obstacles Video
Obstacles Subassembly
Moving Conductor Video
The conductor’s vertical motion is driven by a servo-powered rack-and-pinion system. Because the mechanism uses a Feetech 360° continuous-rotation servo to turn the pinion, the rack and pinion dimensions were designed around the vertical travel required for the avatar to clear all of the obstacles.
The conductor needs to move up and down approximately 150 mm to avoid all the obstacles in the game. To achieve this, the pinion’s outer diameter was set to 78.6 mm, giving it a circumference of about 250 mm. The rack is approximately 232 mm long, which means a 216° rotation of the pinion produces the full vertical displacement needed, and this occurs when the player's loudest sound input is detected.
At the start of the game, the conductor begins in this neutral position. When no sound is detected, the servo rotates the pinion counterclockwise to return the conductor to this starting point.
The servo rotates the pinion counterclockwise as the detected sound level decreases and clockwise as it increases. At moderate sound levels, the conductor rests at approximately the midpoint of the vertical travel.
When a loud sound is detected, the servo rotates the pinion 216° clockwise from its starting position, leading to a vertical displacement of 150 mm for the conductor.
The “avatar servo holder” is mounted to the game’s housing and supports the entire conductor assembly. The rack, avatar connector, steel spring, and avatar are bonded using Loctite super glue, and the rack is held in position through the interference fit between the rack and pinion teeth. The pinion itself is fixed to the servo horn, enabling the servo to control its rotation.
A labeled drawing of the components and their dimensions is shown on the left, and the corresponding CAD files can be accessed here:
The gear-dispensing mechanism uses a Hitec servo that rotates 180° to release 1, 2, or 3 gears at the end of the game. The subsystem stores approximately 55 gears, and the gear holder includes a 4.5 mm slot at its base. Through this slot, a 2 mm-wide dispensing arm mounted to the servo horn sweeps across to push out the bottom gear, which is about 3.2 mm wide. Each 180° sweep dispenses a single gear, and the servo alternates back and forth between its two endpoints to dispense the desired number of gears.
Gear Dispensing Mechanism
The gear-dispensing subsystem is illustrated in the three images on the left, which show the gear dispenser in motion. Below, the CAD drawing highlights the components and dimensions in this subassembly.
The CAD files for each component can be accessed here:
Housing Subassembly
Additional cutouts on the top and middle boards allow the wiring to pass cleanly through the enclosure, and the circuit board is concealed beneath the suspended middle platform and behind the front panel where the start button is mounted. The CAD rendering is shown above, with a detailed dimensioned drawing provided on the right. The CAD file for the housing can also be accessed here: Housing CAD.
After assembly, additional holes were drilled as needed to mount the obstacle components and the conductor subassembly.
The housing was designed in Fusion 360 as a rectangular prism measuring 465.2 mm in both length and width, and 609.6 mm in height. The front panel contains cutouts for the start button, speed potentiometer, gear collector, and the two LED matrix displays. Inside the enclosure, a middle board is suspended approximately 4.5 mm above the base and is fixed in place using finger-joint connections to the side and rear panels. This board includes a slot for gears to drop through and provides structural support for both the rotating obstacle subsystem and the gear-dispensing subsystem.
Decorative elements, including the 3D printed microphone holder and train backdrop, were added to enhance the visual appeal of the game. Intuitive labels such as the game name and the “start,” “fast,” and “slow” markers were laser cut from duron to make the interface easy to understand. All components and decorations were spray painted black and gold to reinforce the steampunk aesthetic. CAD files of all the decorations can be accessed here: Decorations CAD