JoyControl D4E1 - OPTIMA Sensitivity Reducer and Accessory Optimization Package

This project involves designing and developing a specialized add-on package for the OPTIMA Joystick, primarily focused on enhancing precision control and improving ergonomic accessibility for individuals with motor limitations.

Our focus lay initially on introducing a sensitivity reduction mechanism for the joystick to enable more accurate and controlled movements. However, during the development process, we expanded the scope to create a comprehensive package for better overall user experience.

This package includes:

1. Sensitivity Reducer: A core mechanism to allow fine-tuning of the joystick's responsiveness.
2. Button Holders: Custom holders with chamfered edges, designed to improve the ease of activating separate input buttons while preventing accidental presses.
3. Ergonomic Knob Variants: A selection of joystick 'knobs' (handles) to improve comfort and suitability for different grip requirements.

While this system was initially tailored to meet the specific needs of one person with a physical limitation, the underlying concept is broadly applicable. It offers significant value for any user where adjustments to sensitivity, joystick comfort, or button accessibility are crucial.

This project was developed as part of a college assignment of "HOWEST "- West Flanders college of Applied Sciences in collaboration with the "Dominiek Savio" - School, an institution dedicated to supporting individuals with disabilities (https://www.dominieksavio.be/).

The People involved in this project were:

Stephan Chau (stephan.chau.ipo@gmail.com) - Product Designer

Kristína Vlniešková (kvlnieskova@gmail.com) - Product Designer

Matthew Polewiak (matthew.po@protonmail.ch) - Product Designer

Lucia Sanchez (Lucia.sanchezdeocana@gmail.com) -Product Designer

Jasper Pruijmboom (Jasperpruijmboom@hotmail.com) - Occupational Therapist

Through this project, we aim to combine high functionality with universal design principles, making advanced control accessible to those who need it most.

Required Tools

1. 3D Printer
2. Hobby Knife or Pliers

Materials

1. PLA Filament
2. Standard PLA filament in your preferred color.
3. Used for all 3D printed components.
4. Paper or Painter's Tape
5. Small amount.
6. Needed for knob assembly.
7. Velcro (Self-Adhesive)

Used for attaching the button holders to surfaces. Can be sourced from various sites, including https://wildvanstof.be/.

Required Files (STL)

You will need the following STL files for 3D printing the necessary components:

1. Knobs: Knob short brim.stl, Knob short flat.stl, Knob middle brim.stl, Knob middle flat.stl , Knob tall brim.stl, Knob tall flat.stl (Choose one)
2. Button Holders: The 2 separate button STL files (Button enclosure top.stl and Button enclosure bottom.stl)
3. Sensitivity reducer : joystick_enclosure.stl ; joystick 13mm ring, joystick 16mm ring, joystick 20mm ring

1. File: joystick_enclosure.stl
2. Orientation: Print the enclosure on its side. This optimizes strength and minimizes necessary support.
3. Strength : The model is printed on default printer settings (15% infill 2 wall perimeters, 0.20mm layer height) and it works. Recommendation: It would look better and be more durable if printed with 25% infill, 3 wall perimeters and 0.12mm layer height.
4. Post-Processing:
5. Once printed, carefully bend the enclosure along the small connecting piece in the middle.
6. Secure the enclosure's two halves together using a separate ring provided in the file to form the finished casing.

File: Print the 3 files (rings) and test which one provides the optimal sensitivity adjustment.

Strength : Print on default printer settings

1. File: Select one file (Knob short brim,Knob short flat,Knob middle brim,Knob middle flat, Knob tall brim, Knob tall flat)
2. Orientation: Print the chosen knob file with the top surface facing down on the build plate.
3. Strength : Print on default printer settings
4. Support: Use can use support material for this print. Printing this way, with support beneath, ensures the smoothest finish for the part that the user will touch.

1. Files: 2 separate button STL files.
2. Variants: You need to print either the top part or both parts of the holder:
3. Top Part: Print the single part if you plan to attach the holder directly using self-adhesive Velcro.
4. Both Parts: Print both parts if you intend to mount the holders onto the adaptive board (which can also be found on https://www.instructables.com/).
5. Strength : Print on default printer settings

Before proceeding with the assembly of the JoyControl components, you must first remove the current handle (knob) from the OPTIMA joystick shaft.

Installing the Sensitivity Reducer Enclosure

1. Take the printed enclosure (joystick_enclosure), which you bent and secured with the ring, firmly push the assembled reducer onto the OPTIMA Joystick base. It should fit snugly around the shaft mechanism.
2. Next, insert the chosen ring (the piece designed to physically restrict the joystick's range of motion) into the center opening of the enclosure.

Note: Remember to print the 3 rings and test which one provides the optimal sensitivity adjustment for the user's specific needs.

Attaching the Custom Knob (Handle)

1. Take the chosen custom knob (e.g., knobvX.stl) and place it onto the joystick shaft.
2. Addressing Tolerance Issues: Due to variations in 3D printer accuracy, the knob may occasionally fit loosely on the shaft. If this occurs, do not worry:
3. Option A: Wrap a small amount of tape around the top of the joystick shaft.
4. Option B: Roll up a small piece of paper and gently push it into the opening of the knob.
5. Then, firmly push the knob onto the joystick shaft. This simple method works perfectly to secure a loose-fitting knob.

Button Holder Installation

The installation method for the button holders depends on whether you are using the self-adhesive Velcro or the Adaptive Board:

A. Velcro Installation (Top Part Only)

1. If you are using only the top part of the button holder, cut a piece of self-adhesive hook-side Velcro to the size of the bottom of the holder.
2. Peel off the backing and stick the Velcro to the bottom surface of the button holder.
3. The holder can now be securely fixed onto a fabric surface, such as a weighted mat (which was our specific use case).

B. Adaptive Board Installation (Two Parts)

1. If you opted to use the Adaptive Board system, take both printed parts of the button holder.
2. Press the two parts together with the external button securely positioned in between.
3. The assembled button holder can then be placed directly into the designated slot on the Adaptive Board.