Build and Calibrate the Northstar DeckX Headset

[MatthewCroughan]

Julian got the parts for this a few weeks ago, there's a bit lot of 3d printing that's necessary to get it done. @ajlennon is doing most of it as I do not have the filament at home to accomplish it, and he's doing it with PETG.

• The v3.1 headset BOM is here
• Mechanical files are here

Below is a list of parts that are needed. We can check things off as needed. Edit it as needed and place an x inside the boxes. Github does not allow markdown to be added to tables, so in order to keep the formatting of the original .tsv that contains quantity and description columns, I need to place it inside code blocks.

After some vim magic late last night I fixed the formatting so it's kind of presentable as a list

OPTICS BRACKET 3D Prints:

• [x] 1 x # 130-001 - SIMPLIFIED OPTICS MAIN BODY - 15:37 (but I might need to do again with support which is 21:50)
• [x] 1 x # 111-002 - LEFT DISPLAY TRAY - 25cm FOCAL - 3:34
• [x] 1 x # 112-002 - RIGHT DISPLAY TRAY - 25cm FOCAL - 3:36
• [x] 1 x # 113-001 - LEFT ROTATION ADJUSTMENT SLIDE MOUNT - 0:56
• [x] 1 x # 113-002 - LEFT CABLE GUIDE - 0:45
• [x] 1 x # 110-005 - LEFT SLIDE ENDCAP MISSING - Advice is to print 110-006
• [x] 1 x # 114-001 - RIGHT ROTATION ADJUSTMENT SLIDE MOUNT - 0:59
• [x] 1 x # 114-002 - RIGHT CABLE GUIDE - 0:40
• [x] 1 x # 110-006 - RIGHT SLIDE ENDCAP - 0:21
• [x] 1 x # 115-002 - SIMPLIFIED FOREHEAD BASE SHAPE - 1:11
• [x] 1 x # 130-003 - MODULAR LID MAIN - 2:23
• [x] 1 x # 130-004 - MODULAR MOUNT BLANK - 1:38
• [x] 1 x # 130-005 - LEFT MODULAR CABLE CLAMP - 0:33
• [x] 1 x # 130-006 - RIGHT MODULAR CABLE CLAMP - 0:33
• [x] 1 x # 131-001 - SIMPLIFIED DRIVER BOARD MOUNT - 1:46
• [x] 1 x # 131-002 - SIMPLIFIED DP PORT HOLDER - 0:24

Total Print Time circa 35 hours

OPTICS BRACKET Reference Images

Part Number	Design	Print
130-001
111-002
112-002
113-001
113-002
110-005		MISSING - PRINT 110-006
114-001
114-002
110-006
115-002
130-003
130-004
130-005
130-006
131-001
131-002

HEADGEAR 3D Prints:

• [x] 1 x # 210-001 - FOREHEAD MAIN STRUCTURE - 3DPRINT
• [x] 1 x # 210-002 - FOREHEAD HEADGEAR SPAN - 3DPRINT
• [x] 2 x # 210-003 - FOREHEAD HINGE CAP - 3DPRINT
• [x] 2 x # 210-004 - FOREHEAD HINGE BASE - 3DPRINT
• [x] 1 x # 220-001 - REAR HINGE BASE 3DPRINT
• [x] 1 x # 220-002 - REAR HINGE CAP 3DPRINT
• [x] 1 x # 220-001 - REAR HINGE BASE 3DPRINT
• [x] 1 x # 220-002 - REAR HINGE CAP 3DPRINT
• [x] 1 x # 230-001 - LEFT SIDE MAIN SPAN WITH SLIDE BRAKE - 3DPRINT
• [x] 1 x # 230-002 - LEFT BRAKE HOUSING - 3DPRINT
• [x] 1 x # 230-003 - LEFT BRAKE BUTTON - 3DPRINT
• [x] 1 x # 240-002 - RIGHT BRAKE HOUSING - 3DPRINT
• [x] 1 x # 240-003 - RIGHT BRAKE BUTTON - 3DPRINT
• [x] 1 x # 240-001 - RIGHT SIDE MAIN SPAN WITH SLIDE BRAKE - 3DPRINT

HARDWARE:

• [x] 1 x # 500-001 - LEFT REFLECTOR
• [x] 1 x # 500-002 - RIGHT REFLECTOR
• [x] 1 x # 630-001 - 0.304-in OD TORSION SPRING 180 DEG. L-HAND WOUND McMaster # 9271K603
• [x] 1 x # 630-002 - 0.304-in OD TORSION SPRING 180 DEG. R-HAND WOUND McMaster # 9271K668
• [x] 20 x # 640-001 - M2.5x0.45 6mm LONG STEEL FLAT HEAT SCREW 90 DEG CS McMaster # 91420a016
• [x] 2 x # 640-002 - M4x0.7 20mm STEEL BUTTON HEAD SOCKET SCREW McMaster # 91239a152
• [x] 34 x # 650-001 - M2x8mm LONG THREAD-FORMING SCREWS FOR PLASTIC McMaster # 96817a212
• [x] 2 x # 660-001 - M4x0.7mm ZINC PLATED NYLON INSERT HEX LOCK NUT
• [x] 2 x # 670-001 - 5/16 ID x 3/4 OD x 1/16in NEOPRENE WASHER
• [x] 20 x # 690-001 - M2.5x0.45 3.4mm LONG HEAT-SET INSERT FOR PLASTICS McMaster # 94180a321
• [x] 2 x # 700-002 - BOE 3.5-in VS035ZSM-NW0 120HZ LTPS 1440*1600 Module
• [x] 1 x # 800-001 - DISPLAY DRIVER BOARD
• [x] 1 x # 900-000 - eSun 1.75mm PLA Pro (PLA+) 3D Printer Filament Black
• [x] 1 x # 900-001 - MILLER WELDING GEN. III HEADGEAR
• [x] 2 x # 900-002 - 2mm THICK SELF-STICK ANTI-SKID RUBBER
• [x] 1 x # 900-003 - FOAM HEAD PADDING
• [x] 1 x # 900-004 - PADDED CLOTH
• [x] 2 x # 900-005 - 3x10x165mm 6061 AL. BAR SLIDE McMaster # 9146t21

[MatthewCroughan]

Build was successful on September 9th 2020. I made the following tweet afterwards https://twitter.com/MatthewCroughan/status/1303773226301095936

Still Todo

• [ ] Calibrate headset

@goatchurchprime needs to make a scene in the Godot game engine that is capable of helping us tune the headset.

• [ ] Get 6DoF working

We do not have the intel realsense t265 camera that would otherwise give us 6DoF and hand tracking capabilities at the moment. However, @goatchurchprime has suggested that a vive tracker will suffice. We can print an alternative mount for the headpiece that will support this vive tracker.

[ajlennon]

So we've had luck getting the display output on the existing build.

We bought the bits for the 6dof support and in the process decided to upgrade to the more recent mechanical build which is called Deck X. This involved 3D printing new parts so I am going to put down what I'm going to do for these below

[ajlennon]

3D Parts from the ProjectNorthStar DeckX.

Trying to order these in order of assembly documents here

• [x] DeckX_Optics_Bracket.stl (20 hours)
• [x] DeckX_Leap_Motion_Spacer.stl (51 minutes)
• [x] 25cm_Tray.stl (4 hours 38 minutes) (needed to print this with a skirt as it was lifting and deforming - **got a probem with support on this bonding too tightly to the shape to be removed?)
• [x] 25cm_Tray.stl (4 hours 38 minutes) (mirrored ???)
• [x] DeckX_Sensor_Bracket.stl (2 hours 5 mins)
• [ x DeckX_Lid.stl (14 hours)
• [x] DeckX_D-Pad.stl (25 minutes)
• [x] DeckX_Circle_Button.stl (12 minutes) (needs brim)
• [x] DeckX_Dot_Button.stl (12 minutes)

• [x] DeckX_Facial_Interface.stl (52 minutes)

• [ ] 75cm_Tray.stl (N/A - using 25cm trays for now)

Part Name	Design	Print
DeckX_Optics_Bracket
DeckX_Leap_Motion_Spacer
25cm_Tray
25cm_Tray (mirrored)	TBD
Lid
DeckX_Sensor_Bracket
DeckX_D-Pad
DeckX_Circle_Button
DeckX_Dot_Button
DeckX_Facial_Interface

[ajlennon]

Calibration Stand Assembly as per this and this

The right link for these source files is here. Extract and use "Calibration Stand" files, FDM optimised.

We also need a custom model for the T261 mount instead of the ELP camera. This is currently found on the Northstar Discord server here

Done	Code	Number	Name	Print Time
[x]	#310-001	1	BASE MOUNTING PLATE	9 hours
[x]	#310-002	1	LEFT LEFT STAND	6 hours
[x]	#310-003	1	RIGHT LEFT STAND	6 hours
[x]	#320-001	1	DUAL STEREO CAMERA MOUNT BRACKET	1 hour 38 mins
[x]	#320-002	2	STEREO CAMERA STIFFENER	1 hour 25 mins
[x]	#320-003	1	CAMERA CROSSBEAM	4 hours 18 minutes
[x]	?	1	T261 mount	1 hour 16 mins

Also need to buy these parts from the BOM

Done	Code	Number	Description	Source
[ ]	#640-001	8	M2.5x0.45 6mm	LONG STEEL FLAT HEAT SCREW 90 DEG CS	McMaster #91420a016
[ ]	#650-001	22	M2x8mm LONG THREAD-FORMING SCREWS FOR PLASTIC	McMaster #96817a212
[ ]	#690-001	8	M2.5x0.45 3.4mm LONG HEAT-SET INSERT FOR PLASTICS	McMaster #94180a321
[ ]	#700-003	2	ELP USB CAMERA MODULE DUAL LENS STEREO (Use T261 instead???)	Amazon

Name	Model Image	Print Image
T261 mount
BASE MOUNTING PLATE
LEFT LEFT STAND
RIGHT LEFT STAND
DUAL STEREO CAMERA MOUNT BRACKET
STEREO CAMERA STIFFENER
CAMERA CROSSBEAM

[MatthewCroughan]

@goatchurchprime Shall we mark this as complete since we did build and attempt to calibrate/use this, and it is sitting in a box near to your desk now.