Design

The mechanical design consists of three primary components: game housing, sliders, and fighter controls. The housing enclosure serves as the mounting structure for key components such as the sliders and electronics. Designed to be approximately one square foot, the enclosure balances portability with ease of user interaction.

Each fighter will be mounted on a two-track slider system, enabling movement both forward and sideways across the game arena. A DC motor mounted directly beneath each fighter provides limited rotational control for aiming the laser. The control system includes user-operated throttles, allowing players to manipulate their fighters. Each throttle is attached to an encoder, enabling rotational input to control the DC motors. A button on top of each handle allows users to raise the shield and fire the laser.

Manufacturing

The primary manufacturing method for this project is 3D printing, chosen for its simplicity, cost-effectiveness, and ability to produce complex geometries needed to integrate sensors and actuators. Most components, including the fighters and part of the housing, are printed using PLA filament.

The housing box itself is laser cut from 1/4 inch wood with finger joints for mechanical strength. Track sliders, mounts, and adapters are either through-hole bolted connections or adhered to the housing.

Of the more complicated assemblies, the controller throttle is made up of 3 parts: the throttle, potentiometer mount, and cover plate. The potentiometer mounts to the track slider assembly and houses the potentiometer. The throttle is custom fitted to the potentiometer spline and two linear springs restore the throttle back to neural upon release. The cover hides this assembly and ensures that wires will not snag during use.