Omni Launch System (OLS) | Prusament Edition

Omni Launch System (OLS) | Prusament Edition

The Ultimate Modular Spool Upcycle

Don’t toss the toss-able. Inspired by Prusa's philosophy of modularity, upgradability and customisation while keeping things open-source, the Omni Launch System (OLS) transforms your empty Prusament Spools into a high-performance, modular kinetic platform. Designed specifically to utilize the structural integrity and hexagonal geometry of the Prusament core, the OLS is more than just a toy, it is an open-source standard for 3D-printed ballistics and aerodynamics.

The OLS is a handheld, simple rubber band powered rail-guided launcher featuring a Prusament inspired grip / handle using the spool as a modular platform. The 'Omni-Modular Architecture' provides you a "Plug-and-Play" system that allows you to switch between gliders, disks, and darts in seconds providing you a consistent, repeatable, and powerful launch every time. 

I have provided OLS-Blanks and Step Files to empower the community to design their own specialized gliders, projectiles or attachments to make it more fun.

Projectiles Included (V1.0)

1. The Aero-Sled: Optimized for 3D-printed or cardboard gliders (provided they use the rail guide).

2. The Disc-Driver: Designed for 30mm 3D printed or laser cut disks.

3. The Foam-Striker: An attachment for standard 7.2cm foam (Nerf) darts.

Material / Parts from the store :

1. Small / Medium / Large size rubber bands x 2 

2. 30mm M3 Bolt x 1 (3D printed alternative provided)

3. Nerf Foam Darts (7.2cm)

4. Empty Prusament Spool (New) - Split the spool into parts you get both sides separated. (Alternative 3D printable file from Prusa provided in the files below.)
   

All files have been uploaded as 3mf but due to uncertain cross compatibility issues, I had issues with getting the material and parameters on Prusa Slicer - BL Slicer.

All parts are designed to be printed without supports.

Parts to be printed in PETG : 

1. Rail - OLS 
   Can be printed at 0.16 / 0.2mm layer height
   Bottom Surface Pattern - Concentric

All the other parts can be printed using PLA
Layer height : 0.16 / 0.2mm  
Walls / Perimeters : 3 (minimum)

Note - For printing the 'Spool - Grip Connector' ensure the 'Seam Position - Back' is enabled in the slicer! If the seam ends up inside the connector, it will be difficult to insert the 'grip / handle' as it interferes with the tolerances.

Assembly :
Part 1 - The Striker

Parts needed :

1. Anchor for Rubber Band x 2

2. Guide for Rubber Band x 2 (optional)

3. Rubber bands x 2

4. 'Rail Runner'

You can use just two 'guides' for the rubber band to adjust the tension of the rubber bands or even control where the 'Rail Runner' stops on the rail. (I'm still experimenting with it - If you don't use these guides, there is a high probability of the 'Rail Runner' running out of rail (LoL) and you will have to insert in back again every time you launch something)

Step 1 - Insert the rubber band into the 'Anchor for Rubber Band' and use the most common 'Larks Head Knot' to attach the rubber band on the anchor. Repeat the step using the 2nd rubber band. Refer to the images if necessary.

Step 2 - Take one rubber band with the 'Anchor' and loop the other end of the rubber band to the circle of the 'Rail Runner' using the 'Larks head Knot'. Repeat the step using the other rubber band for the other circle of the 'Rail Runner'. You will now have the rubber bands looped to the 'Anchor' to the left and right side of the 'Rail Runner'.

Your 'Striker' is now ready! Keep it to the side for now along with the 'Guide for rubber band' for later.

Assembly :
Part 2 - Lock and Load

Parts needed :

1. Rail - OLS

2. Trigger Mechanism V2

3. 30mm M3 Bolt x 1 OR 'Trigger - Fulcrum Lock'

4. Spool Grip Connector

5. Handle / Grip'

6. Empty Prusament Spool - Disk 

Step 1 - Take the 'Rail - OLS' and insert the 'Trigger Mechanism' in the thin, flexible end of the of the rail. The design allows only one way of inserting the 'trigger mechanism' into the rail. Be careful while inserting as this thin, flexible part can break or bend if you are not careful. You will hear a satisfying click to know when both the parts are locked in together.

Step 2 - Take 'Empty Prusament Spool - Disk' and insert the hexagons of the rail in the centre of the spool along the branding as shown on the photo. The design allows only one way of attaching this rail on the spool as intended.

Step 3 - Fold the 'Trigger Mechanism' attached to the rail sandwiching the spool between the rail and the folded 'Trigger Mechanism' as shown in the image.

Step 4 - Insert the 'Grip' into the 'Spool Grip Connector' using the guides on both parts.

Step 5 - Attach this 'Spool Grip Connector' using the hexagons into the 'Empty Prusament Spool - Disk'. The connector is designed to have the 'trigger mechanism' to be sandwiched between the spool and the connector. 

Step 6 - The 30mm M3 Bolt x 1 OR 'Trigger - Fulcrum Lock' and insert it through the hole of the 'Spool Grip Connector' passing through the trigger mechanism's hole to the other side. If you are using the M3 bolt, you can tighten it and lock it into place. If you are using the 3D printed 'Trigger - Fulcrum Lock', it should friction fit into place. 

Congratulations! Your trigger mechanism is now ready to be loaded!

Assembly :
Part 3 - Getting it Ready!

Parts needed :

1. Sub-assembly : The Striker

2. Sub-assembly : Lock and Load

3. Glider 1 
   OR
   -Disk 30mm x 5mm
   -Disk Guide Attachment V2
   OR
   -Nerf Barrel - 7.2cm Ammo
   -Nerf Darts

Step 1 - Take the Striker sub-assembly and insert the 'Anchors' near the front of the rail in the 3rd or 4th hexagon on each side of the rail. Maintain symmetry for equal force distribution. 
You can try other placements for these anchors on the spool as per your liking.

Step 2 - Insert the 'Rail Runner' on the 'Rail - OLS'.

Step 3 (Optional) - Insert the 'Guide for Rubber Band' at a distance of 4-6 hexagons or as per your liking. Insert the rubber bands through this guide.

You can use just two 'guides' for the rubber band to adjust the tension of the rubber bands or even control where the 'Rail Runner' stops on the rail. If you don't use these guides, there is a high probability of the 'Rail Runner' running out of rail (LoL) and you will have to insert in back again every time you launch something.

Wohoo! Your Omni Launch System for Gliders is now ready!

The Aero-Sled :

Step 4 - Just pull back the 'Rail Runner' using the circle or hexagon until it latches onto the 'Trigger Mechanism'. Load your glider on the rail and see it fly a distance of at least 10 meters! Be careful while trying this out inside your house.

P.S. - You may have to curve the wings of the glider upwards for a better flight length.

The Disc-Driver:

Step 4 - Insert the 'Disk Guide Attachment V2' in the front of the rail. There are 4 possible slots available to attach this, choose your own.

Step 5 - Insert the 'Disk 30mm x 5mm' in the 'Disk Guide Attachment' and pull back the 'Rail Runner' using the circle or hexagon until it latches onto the 'Trigger Mechanism'. You are now locked and loaded. 

DO NOT AIM AT HUMANS, ANIMALS OR ANY LIVING BEING. 
Be careful while trying this out inside your house.

The Foam-Striker:

Step 4 - Insert the Nerf Barrel - 7.2cm Ammo' in the front of the rail. Ensure the barrel is FACING INSIDE towards you. There are 4 possible slots available to attach this, I would suggest using the outermost slot for this.

Step 5- Insert the 'Nerf Darts' in the 'Nerf Barrel Attachment' and pull back the 'Rail Runner' using the circle or hexagon until it latches onto the 'Trigger Mechanism'. You are now locked and loaded. 

Tip - The range of these darts vary upon the placement of them within the barrel; i.e. how far is the orange / blue tip hanging out.

Design Your Own Kit :

I have provided step files of the following :

1. Design Your Own - Glider

2. Design Your Own - Attachment? Shooter? Be Creative!

3. Design Your Own - Handle / Grip

Looking forward for a lot of remixes! :D

Enjoy your Omni Launch System for Nerf darts!