All notable Mechanical changes will be documented in this file.
BOM for Update 3.1 Assm
Cable guides (#113-002, #114-002)
Simplified folder structure
Updated BOM with links
Exported updated CAD STEP files of assemblies
Associated part numbers with simplified assm (#130-003, #130-004, #130-005, #130-006)
Flattened bottom for easier printing (#112-002, #111-002)
Thickened and fillet corners for strength (#230-001,#240-001)
Keyed mates for faster assembly (#220-001,#220-002,#210-003,#210-004)
Thickened for strength, offset edges, removed old cable guide holes (#130-005, #130-006)
Added L+R labels to headgear for easier assembly (#230-000, #240-000)
Added corresponding screwholes for cable guides (#113-001, #114-001)
New endcap with M2.5 screw mount (#110-005, #110-006)
Cutout size and shape for al. bar slides (#110-003, #230-002, #240-002)
Modular lid and Vive tracker mount (#130-002, 3, 4, 5, and 6)
Blank mounting plate STEP file
New slide end cap with cable mount (#110-003)
Chamfer on optics bracket display screws, removed lip around rubber washer (#130-001 and #110-001)
Added simplified optics assembly (#130-000)
This folder contains the mechanical assets necessary to build a Project North Star AR Headset with calibration stand.
Mechanical Release 3 bundles together all the lessons we learned into a new set of 3D files and drawings. Its main objective is to be more inviting, less hacked together, and more reliable. The design includes more adjustments and mechanisms for a larger variety of heads and facial geometries. Overall, the assembly is lighter, more balanced, and stiffer.The parts were designed for an FDM style 3D printer
This is a work in progress. This is not a finished guide, nor end-user friendly. Major sections are missing. Assembly requires care and patience. Nothing worth having is ever easy.
Open the Headset Mechanical Assembly and construct each sub-assembly as illustrated. A full list of the parts needed can be found in the Headset Bill of Materials (BOM). Not all sub-assemblies are required as there are multiple designs to choose from. Additionally, the CAD files are included in STEP format to help design new parts.
The headset consists of two basic sections: the optics #100-000 and headgear #200-000. The optics subassembly currently has two variants: Release 3 optics and Update 3-1 (i.e. the simplified optics assembly). The headgear assembly utilizes the rear adjustment mechanism from a Miller branded welder’s helmet, but several models can be made to work.
Functionally, the two optics assemblies are the same. Release 3 is closer to the original design aesthetic and it’s marginally (8g) more lightweight. On the other hand, Update 3-1 halves the print time by removing the need for supports on the sides. Overall, the simplified 3-1 bracket is easier to print with lower print failures and stiffer too. It’s recommended to start with the simplified Release 3-1 optics assembly for the first build. See drawing #100-000 for more information.
All development was done using eSun's PLA Pro / PLA+ filament. We've found it to be strong, easy to print, and have great surface finish.
A build plate of approximately 250x200mm is recommended for the largest parts
Parts may need to be rotated to align with print bed.
Some parts have optimized versions (labeled “FDM OPTIMIZED”) with extra plastic tabs that need removing. These versions aid in minimizing warping and gripping the print surface.
.25mm layer height, 2 perimeter shells, 15% infill Filament: eSun PLA Pro (PLA+) 3D Printer: MakerGear M2 Slicer: Simplify 3D
Several parts in the optics assembly use brass inserts for increased clamping load and the ability to swap out the components multiple times without wear. These inserts need to be heated above the plastic's melting point and pressed into the plastic. It's recommended to use an installation tip designed for brass inserts.
Demonstration of using a soldering iron to install brass inserts. The wire cutters are used to prevent the insert from pulling back out when not using an installation tip.
Parts that require inserts:
Installing brass inserts into the optics bracket is optional. They're intended as mounting points for future testing.
The headgear assembly includes parts that print flat but bend to fasten to each other. Although not necessary, it’s suggested to drape these parts around a form while the 3D print is still soft from the heated print bed. This minimizes strain inside the plastic and prolongs the life of the part.
Preheating the print bed to 70C softens a print enough to shape the part
This guide is also available as a PDF:
A video guide from Tasuku Takahashi is available below, it's best to supplement the written documentation with this video. If you run into problems or have questions, feel free to reach out on the discord.
Item No 6 (#230-004) of the Left Brake Assembly was removed and thus no longer packaged due to undesired cable catching. The new method of managing cables is by attaching a zip tie to the end cap.
Item No 6 (#230-004) of the Left Brake Assembly was removed and thus no longer packaged due to undesired cable catching. The new method of managing cables is by attaching a zip tie to the end cap.
Part number
Quantity
Description
Source
#110-001
1
OPTICS BRACKET MAIN BODY
3DPRINT
#110-002
2
SLIDE ENDCAP
3DPRINT
#111-001
0
LEFT DISPLAY TRAY - 75cm FOCAL
3DPRINT
#112-001
0
RIGHT DISPLAY TRAY - 75cm FOCAL
3DPRINT
#111-002
1
LEFT DISPLAY TRAY - 25cm FOCAL
3DPRINT
#112-002
1
RIGHT DISPLAY TRAY - 25cm FOCAL
3DPRINT
#113-001
1
LEFT ROTATION ADJUSTMENT SLIDE MOUNT
3DPRINT
#114-001
1
RIGHT ROTATION ADJUSTMENT SLIDE MOUNT
3DPRINT
#115-001
1
FOREHEAD REST BASE SHAPE
3DPRINT
#120-001
1
HALO MAIN BODY
3DPRINT
#120-002
1
HALO LID
3DPRINT
#121-001
1
HALO ELECTRONICS HOLDER
3DPRINT
#121-002
1
HALO ELECTRONICS DP PORT HOLDER
3DPRINT
#130-001
0
SIMPLIFIED OPTICS MAIN BODY
3DPRINT
#131-001
0
SIMPLIFIED DRIVER BOARD MOUNT
3DPRINT
#131-002
0
SIMPLIFIED DP PORT HOLDER
3DPRINT
#210-001
1
FOREHEAD MAIN STRUCTURE
3DPRINT
#210-002
1
FOREHEAD HEADGEAR SPAN
3DPRINT
#210-003
2
FOREHEAD HINGE CAP
3DPRINT
#210-004
2
FOREHEAD HINGE BASE
3DPRINT
#220-001
2
REAR HINGE BASE
3DPRINT
#220-002
2
REAR HINGE CAP
3DPRINT
#230-001
1
LEFT SIDE MAIN SPAN WITH SLIDE BRAKE
3DPRINT
#230-002
1
LEFT BRAKE HOUSING
3DPRINT
#230-003
1
LEFT BRAKE BUTTON
3DPRINT
#230-004
1
LEFT CABLE GUIDE
3DPRINT
#240-001
1
RIGHT SIDE MAIN SPAN WITH SLIDE BRAKE
3DPRINT
#240-002
1
RIGHT BRAKE HOUSING
3DPRINT
#240-003
1
RIGHT BRAKE BUTTON
3DPRINT
#240-004
1
RIGHT CABLE GUIDE
3DPRINT
#500-001
1
REFLECTORS
#630-001
1
0.304-in OD TORSION SPRING 180 DEG. L-HAND WOUND
#630-002
1
0.304-in OD TORSION SPRING 180 DEG. R-HAND WOUND
#640-001
28
M2.5x0.45 6mm LONG STEEL FLAT HEAT SCREW 90 DEG CS
#640-002
2
M4x0.7 20mm STEEL BUTTON HEAD SOCKET SCREW
#650-001
36
M2x8mm LONG THREAD-FORMING SCREWS FOR PLASTIC
#660-001
2
M4x0.7mm ZINC PLATED NYLON INSERT HEX LOCK NUT
#670-001
2
5/16 ID x 3/4 OD x 1/16in NEOPRENE WASHER
#690-001
21
M2.5x0.45 3.4mm LONG HEAT-SET INSERT FOR PLASTICS
#700-002
2
BOE 3.5-in VS035ZSM-NW0 120HZ LTPS 1440*1600 Module
#800-001
1
DISPLAY DRIVER BOARD
#900-001
1
MILLER WELDING GEN. III HEADGEAR
#900-002
1
2mm THICK SELF-STICK ANTI-SKID RUBBER
#900-003
1
FOAM FOREHEAD PADDING
#900-004
1
FOAM BACKED FABRIC
#900-005
1
3x10x165mm 6061 AL. BAR SLIDE
