Introduction: Busy Button Box - Montessori-style Electronic Board Toy for Toddlers
忙碌的董事会are great for toddlers to practice their motor skills, independent play, and concentration. However, my 18-month old has spent far more time playing with light switches around the house than any busy board!
我购物了一个具有电动元素和类似蒙台梭利的设计的电子按钮盒玩具，但没有任何东西，所以Busy Button Box被发明！
- If you have feedback on how to make this project better, please share! I normally invent STEM activities for kids so this project is outside of my expertise. I'm sure there's room for improvement!
Safety notice: This product of this Instructable has not been reviewed by any child safety agency. Only use under close adult supervision.
- Hot glue gun
- Drill with 1/16" bit
- 3D printer(I use a Creality CR-10)
- 激光切割机(I use a basic Glowforge)
- Assorted small wood screws(M1.7x4, M1.7x8, and M2x12)
- 各种尼龙螺母、螺栓和垫圈(sizes M3x20 and M4x20)
- Strap-style cable organizers(x2)
- #8 1/4" wood screws
Buttons and switches:
- Standard US single-pole toggle light switch
- Toggle and paddle switch cover plate
- 12mm toggle push buttons（x5）
- 21mm on/off rocket switch
- 12mm metal momentary push button(Optional)
- 5mm LEDs, assorted colors（x4）
- 5mm LEDs, RGB fast phasing（x3）
- 3V solar string light replacement bulbs(x2)
- 变速箱“ TT”电动机
- Low voltage motor speed controller
- Motor mount
- 3D printed controller knob (file attached in step 9)
Cut out the 6mm wood pieces with a laser cutter using 6mm laser-safe Baltic birch plywood. On a basic Glowforge laser cutter, the settings are充满电and 115 speed. Plywood width may vary so be sure to test your settings.
Step 2: Glue the Box Together
On all 4 the side pieces: Apply wood glue to the inside of the slots and to the side of the tabs facing the main top piece.
- Tip: Use an old paintbrush to apply the glue. It's fast and helps get the glue into the corners.
Clamp the box together from all sides, then use mini clamps or binder clips to clamp the thin edge of the large opening to the side of the box. Make sure the opening for the 21mm master toggle switch is on the front of the box.
- Tip: If you don't have enough clamps, wrap the box in a rope or bungee cord, then put something heavy on top.
Next, prepare to coat the box in wax by covering the corners with masking tape. 3/4" width tape is ideal, but 1" will work too.
What's the masking for?In the last step, the foam safety bumpers are attached to the corners with adhesive. The adhesive doesn't adhere well to the waxed wood, so masking the corners will ensure a better bond.
Thoroughly coat the outside of the box and back plate with wax according to the wax's instructions. This gives the box some protection from sticky toddler hands!
Step 4: Install the Buttons and Switches
Prepare the household switches by wrapping 3-4" (8-10cm) lengths of bar wire around the terminals. Doing this now is much easier than later, after the switches have already been installed.
Attach the switches in their respective cutouts using short wood screws.
- 重要的！Make sure the top of the switches are next to the acrylic window cutout. The word "Top" will be embossed onto part of the switch.
Attach the toggle and momentary buttons into their respective cutouts. You can order the colors of the momentary buttons however you want.
- 图所示的12mm矩RGB LED按钮是金属，但是如果需要，您可以使用另一个塑料。
Step 5: Install the 5mm LEDs
For the assorted color LEDs: Match the colors of the LEDs with the buttons. Rotate the LEDs so the positive terminal is facing the buttons. Spread the wire leads apart, then apply a generous glob of hot glue behind the LED.
Step 6: Install the Light Bulb Mounts
The lightbulbs will be mounted inside the box with large strap-style cable organizers. Prepare the cable organizer with a lead wire for the bulb by wrapping a 4" (10cm) length of bar wire several times around the middle of the strap.
Why not solder wire onto the bulb?The heat from the soldering iron can destroy the electronics inside the light bulb. Also, the metal casing requires a very high temperature to form a solder bond - even with rosin - so it's very easy to overheat and destroy the lightbulb's circuitry.
Attach the cable organizers above the center of the switches. Align the edge of the cable organizer base with the acrylic window cutout.
Use a small screw and washer to secure the base of the strap to the box. The other side of the box will be covered with the switch plate, so it's okay if the screw goes through the wood.
Step 7: Install the Lightbulbs
Create a wire lead for positive terminal of the bulb by cutting a 4" (10cm) length of bar wire, then bend a small loop on one end. Position the loop over the bottom of the bulb, then hold it in place with a tightly stretched piece of electrical tape.
- The tape also provides some friction to help keep the bulb strapped in.
Step 8: Install the Battery Holder and Motor Controller
Use two small screws (M1.7x4) to secure the battery holder as shown.
Use four small bolts with nuts and washers to hold the motor controller in place. I used M3 nylon bolts, then trimmed off the excess and used a little CA glue to ensure the nuts doesn't loosen over time with the vibrations from the motor.
Fit a M4 bolt into the motor mount, then snap the mount onto the metal motor casing. Make sure the copper motor terminals are exposed.
Use a nut to secure the motor to the box. Trim off the excess bolt and apply a little CA glue to ensure it doesn't loosen.
3D print the knob with at least 25% infill. To attach the knob: First turn the metal dial counterclockwise until it clicks into the off position. Use one hand to support the motor controller dial, then push-fit the knob on. I suggest orienting the knob so the indicator circle is pointing to the lower left corner of the box.
Lastly, fit the laser cut propeller onto the plastic motor shaft. All the hardware installation is complete!
Step 10: Connect the Electronics
I made this using circuit-diagram.org.
Step 11: Finish and Test the Electronics
Step 12: Add the Acrylic Covers
Use 1.7Mx8 screws to attach the acrylic covers over the window cutouts. Tighten slowly by hand to avoid over-tightening and cracking the acrylic.
Align the backplate with the box, then hold it in place with clamps. Using the precut holes in the backplate as a guide to drill pilot holes into the sides of the box using a 1/16" bit.
Keep the clamps in place, then use M2x12 screws to attach the backplate to the box.
Apply furniture pads to the corners of the box. These protect the surfaces that the box is placed on.
- Cut 2" (5cm) foam pieces (x4).
- Cut the adhesive strips into 2" (5cm) pieces (x8).
- Apply the adhesive strip to the inside faces of the foam corner bumper.
The box is complete! If you made one yourself or have any feedback on this design, please share with me. I'm unfamiliar with a lot of the materials and processes that were used in this project so I'm open to redesigning the button box again in version 4!