Airbus A320 Flaps Mechanism

Design to recreate the stepped and gated functionality of the Airbus A320 Flaps lever. 

Design objective was to create a realistic feel, with a smooth, solid and weighty action. The design therefore includes steel and brass shafts plus an (optional) rotary damper. It also uses a rotary hall angle sensor for reliability in place of a standard potentiometer.  The design could be simpler and use less plastic, but it is optimised to feel solid rather than minimise material for mass production.

Side Frames and Slot Light Blocker can be printed in PLA. All other parts, including Gears and Notch and Pivot parts should be printed in PETG, 100% infill for strength, particularly for parts with grub screws.

Assembly is straightforward. Use CAD images and photos as guide. Order of assembly is as follows:

• Fit small bearings to Notch Body Lower
• Glue 2mm pins in Pivot Body
• Assemble one Notch Body Side to Notch Body Lower and Notch Body Upper (4 x M3 screws)
• With Pivot Body in place, assemble other Notch Body Side (4 x M3 screws)
• Insert lever hollow steel rod in top of Notch Body Upper
• Slide lever sold brass rod in place, through spring located in Notch Body and Pivot Body recesses (This is a bit fiddly)
• Tighten M3 grub screws to fix parts in place on shafts
• Insert Pivot Body plastic shaft through main pivot bearings on Side Frames
• Screw Side Frames together (4 x M4 screws)
• Add spacer and Main Shaft Gear. Secure with M3 grub screw
• Add gears to Hall Effect and Damper
• Attach Hall Effect (aligning rotation of gear for correct output) and Damper (M3 and M4 screws)
• Add Slot Light Blocker. Can glue in place, but will be clamped by Panels
• Pass lever through Panel slot
• Add knobs

Design uses M3 and M4 cap head hex screws and M3 grub screws for assembly, plus the following parts which are all available from Amazon and B&Q in the UK, plus Ali Express as of March 2024:

Rotary Hall Effect Angle Sensor:

https://www.aliexpress.com/item/1005005806329401.html?spm=a2g0o.order_list.order_list_main.11.21ef180239AE3F

Rotary Damper:

https://www.amazon.co.uk/gp/product/B01N1XDTLX/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

22mm x 8mm x 7mm Bearings:

https://www.amazon.co.uk/gp/product/B08H2853D3/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

10mm x 5mm x 4mm Bearings:

https://www.amazon.co.uk/gp/product/B082PQ6VNJ/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Compression Spring from spring kit:

https://www.amazon.co.uk/gp/product/B000QF7JTO/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

8mm outer diameter 95mm long steel tube:

https://www.diy.com/departments/varnished-cold-pressed-steel-round-tube-l-1m-dia-8mm-t-1mm/253921_BQ.prd

6mm diameter 205mm brass rod:

https://www.amazon.co.uk/gp/product/B0BWN9KWHH/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

2mm Pins:

https://www.amazon.co.uk/gp/product/B07M63LBSQ/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Designed to work with my Flaps lever knobs:

https://www.printables.com/model/786201-airbus-a320-flaps-handle

And my Flaps Panels:

Airbus A320 Flaps Panels by MANTOGA | Download free STL model | Printables.com

My matching Speedbrake Panel and mechanism is available on MakerWorld:

https://makerworld.com/en/models/1605940-airbus-a320-speedbrake-mechanism#profileId-1693404

** Added Rotary Damper Adapter plate and smaller damper gear to allow use of Bansbach C2 rotary damper (in place of D3), which provides less damping and therefore a lighter and potentially a more realistic feel. Having tried both, I much prefer the lighter feel of this smaller C2 damper.

https://www.amazon.co.uk/Bansbach-Easylift-FRT-C2-201G1-Dampers-Standard/dp/B01N0VYKRV/ref=sr_1_17?crid=YMJKZ3HFQUV2&dib=eyJ2IjoiMSJ9.pBAEsPmNyiQMkcLz8c6ElV0tbU-mPWYAGNzJO_snQx7GEK_JyviroMK-IVsZzBancYMrEZ9-CQoV5oaSYQYQNyhMkGWy80FMjHQhv_IoHauCW1FgaBL2sCKAaZ_UR6zXG9cx11lOxo6cPUd8Vzy7wGEagmcXGsvjyg9R4WxNb59ZzKFiGmwP-6Jy1NB_zmvqZ8DTH38mowT_7W849pzJEe38tHTMuphzgUWJo79bLN5UOjFw7_GxIVUphsAIn1TRA5yISTO38kIXUkUzNw3wzfIuI7dICB_XEdjAAXWlwgQ.G2OTvoRGNy-5yGNjlq7WVZuEELw-Eohl9yBmztZlNf4&dib_tag=se&keywords=rotary%2Bdamper&qid=1720210180&sprefix=rotary%2Bdamper%2Caps%2C73&sr=8-17&th=1