Star Trek The Next Generation Hypospray Prop

Tentative note 2022.04.25:

This will get revised at some point, as main sound board will be changed to an adafruit qtpy with a battery backpack and a mono amp board. This will minimize soldering required, and give potential for some kind of function to the 2nd button in the top pyramid section. Plan is to have a cutout for usb-c to allow recharge by uncovering plug if taking off one of the grips. Cutouts for M2 screws will be added to a v2 to stabilize the neck section.

Otherwise I may try to rebuild this with a board from here: 

https://www.dfrobot.com/product-2232.html

This is designed to use the following board connected to the main button for the hypospray sound. Board edges will require some shaving, and wires may need to be re-oriented, or new wires may need to be soldered to keep its profile as slim as possible.

This old link doesn't really fit for the dimensions required anymore: https://www.amazon.com/gp/product/B01M35VHY5

If you don't care about having this actually play any sound, you're more than free to print all parts and glue them together once you've got them fitted together. Even when everything is glued together, a standard insulin vial can be popped in/pulled out if the grip section is printed in TPU.

Board will need to be fit into the body diagonally. I did not measure the amount of wire I used, so mine has a tighter fit with all the clumped up slack.

All parts can be assembled without glue, except for the buttons- I used sugru for the smaller hardware button against its backing panel (smaller button has a click in/click release action). If you don't want the buttons to press in, you can just glue them.

All threaded parts (neck, spray tip) should be M20 compatible.

Demo of print with sound board: https://www.youtube.com/watch?v=PBd0jTCIozM

Assembled pyramid section: https://youtu.be/ze3CLa-kbG4

I soldered jumper wire to the board, and connected jumper wire to the main button. I also soldered headers to the speaker. I placed 1 of each of these in the pyramid corners behind the main button, but only connected wires to one of them: https://www.adafruit.com/product/3101

A click on/off toggle button (for the secondary one) is here, https://www.adafruit.com/product/3870

but I ended up using this, having shaved down the right side until I started to see the internal metal bar: https://www.microcenter.com/product/497123/leo-sales-ltd-mini-button-yellow-switch---4-pack

Speaker used can be found at digikey: https://www.digikey.com/product-detail/en/cui-devices/CLS0201MP/102-1542-ND/1630856

Battery was taken from an 8bitDo kit, and was originally intended to make a psx classic controller wireless. Any 100-150mah battery should work, as long as it is not over 25mm wide. The battery I used has been able to sit idle for months and still work - you can solder the battery wires to the board and recharge it from the micro usb port. The body lid can be re-opened when the battery needs to charge, since no glue is used to secure it.

Sound file was downloaded from trekcore.com. I had to save their file in a different format to upload to the sound board, which I did using Audacity and copy/paste from within file explorer. Those files are on my github: https://github.com/lambtor/Hypospray

This model is 10% larger than the scale recommended in the original that this was remixed from. That was done to enable the body to allow fit of a standard insulin vial (u/100). Do NOT go out and buy an insulin vial just for this project - ask people you know and I'm sure you'll eventually find an acquaintance who can give you an empty one. If you absolutely cannot find an empty one, you can print the vial included.

I have not printed the last revision made to the body lid. It should cause the screw-in parts to line up, but I haven't verified it.

Print Settings

Printer Brand:

Anycubic

Printer:

All-metal Mega

Rafts:

Doesn't Matter

Supports:

Yes

Resolution:

Highest resolution possible

Infill:

I used 100%

Filament: Fillamentum, Neat Filaments PLA, TPU

Rapunzel Silver, Gunmetal

Notes:

Print the most complicated pyramid part with circular hole facing down. This minimizes supports and gives a cleaner layer look on the button face. Use Lines for bottom layer of pyramid print to give the face a more uniform look where the nozzle screws on.

Fillamentum "Rapunzel Silver" PLA for body, neck, pyramid, body lid, pyramid base.

Fillamentum "Gold Happens" PLA for nozzle, buttons.

Neat Filaments Gunmetal TPU for the body grips.

I don't expect anyone to print the vial - the model for it was added in case anyone wants to try printing it with a clear resin or possibly a translucent colored PLA.