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Thread: New Quadrant controls

  1. #1
    Supporting Member Kendy for the State's Avatar
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    New Quadrant controls

    Almost ready to start producing these, just working on some manufacturing details:

    GF1 - Combat Commander

    5 Quadrants (levers easily removable for different sizes/colors - optional detents)
    3 Trim controls with position indicator
    18 2-position full-size momentary switches (36 digital buttons)


    GF1.png


    GF2 - Bomber Commander

    8 Quadrants (levers easily removable for different sizes/colors - optional detents)
    20 2-position full-size momentary switches (40 digital buttons)

    GF2.png
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  2. #2
    ATAG Member ATAG_Freya's Avatar
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    Re: New Quadrant controls

    First one to 'like' the OP gets one for free?


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  4. #3
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Quote Originally Posted by ATAG_Freya View Post
    First one to 'like' the OP gets one for free?

    TANSTAAFL !

    Quote Originally Posted by Kendy for the State View Post
    Almost ready to start producing these, just working on some manufacturing details:

    GF1 - Combat Commander

    5 Quadrants (levers easily removable for different sizes/colors - optional detents)
    3 Trim controls with position indicator
    18 2-position full-size momentary switches (36 digital buttons)


    GF1.png


    GF2 - Bomber Commander

    8 Quadrants (levers easily removable for different sizes/colors - optional detents)
    20 2-position full-size momentary switches (40 digital buttons)

    GF2.png

    Sent from my XT1635-01 using Tapatalk
    Windows 10 Pro 64-bit
    Intel Xeon 31230 @ 3.20GHz (4 cores - 8 threads)
    16GB RAM
    NVidia GeForce GTX1080 (Asus Rog Strix GTX 1080)
    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  5. #4
    Team Fusion 69th_Zeb's Avatar
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    Re: New Quadrant controls

    Awesome. I like the GF2. With some RLM/RAF Tamiya paint mixes and decal paper one could finish it like a custom model. 1:1 scale.

    Hopefully as people fly around with you they can feel comfortable buying something they'll know they can ask support for from someone they regularly interact with.

    I know there's a bewildering number of forum sub-menus, but would be nice to have a dedicated forum section for custom simpits and accessories -similar to SimHQ.

    ~S~!

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  7. #5
    Supporting Member Brennus54's Avatar
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    Re: New Quadrant controls

    Have you a web site where we can purchase/pre-purchase these peripherals Kendy ? (maybe a Wip website ?)

    If not, what will be the price for each.

    I love this kind of project, congratulation for your work.

  8. #6
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Quote Originally Posted by Brennus54 View Post
    Have you a web site where we can purchase/pre-purchase these peripherals Kendy ? (maybe a Wip website ?)

    If not, what will be the price for each.

    I love this kind of project, congratulation for your work.
    Thanks for your kind words.

    For now I have set up a seller account on Amazon, keyword "Gearfalcon",though I will probably do a Shopify account so people can order direct, and I can offer discounts to people who fly here.

    I am aiming for around the $200 price point, though I am still working on materials and labor calculations. At this point I am just making them myself with cast resin, so no mass production. If they are popular enough I will look into having some injection molding done, and with economies of scale hopefully can bring the price down.

    I won't accept money for a non-extant product, so I'm afraid you'll have to wait for the official release
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    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  10. #7
    Supporting Member Brennus54's Avatar
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    Re: New Quadrant controls

    YEAH !

    yes sir ,
    i may have a partnership to propose to you in the following weeks

    I think this forum reveal some vocation haha.

    See you in the air.

    EDIT : Oh, you are from USA, this can pose some... problems lol, we will see
    Last edited by Brennus54; Apr-07-2017 at 13:41.

  11. #8
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Here's an early prototype...


    Sent from my XT1635-01 using Tapatalk
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  12. #9
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Reviving this so you don't think it's dead!
    I've found that a lot of my smaller parts just are not well suited to cast resin molding, so I've spent the last few months learning about machining and injection molding. Doing things on a shoestring, so can't afford to have all these parts professionally made.

    Anyway, bought a CNC milling machine and a benchtop injection molding machine, and here are some results from my first molds. Hope to have product soon!

    IMG_20190219_114858688.jpg
    IMG_20190220_150010000.jpg
    IMG_20190220_150417878.jpg
    IMG_20190220_153158349.jpg
    IMG_20190220_155302531.jpg
    1550777016425461.jpg
    Last edited by Kendy for the State; Oct-08-2019 at 17:09.
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  13. #10
    Supporting Member Kwings714's Avatar
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    Re: New Quadrant controls

    That is some serious aviation gear/setup. Are you planning to mass-produce. I don't think its would be an easy DIY. Due to molding and accessing to the CNC/Milling.
    What are you planning to with the pneumatic/hydraulic cylinder? Would you mind provide us the micro-film. Just kidding.
    Last edited by Kwings714; Mar-20-2019 at 00:20. Reason: spelling
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  14. #11
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Quote Originally Posted by Kwings714 View Post
    That is some series aviation gear/setup. Are you planning to mass-produce. I don't think its would be an easy DIY. Due to molding and accessing to the CNC/Milling.
    What are you planning to the pneumatic/hydraulic cylinder? Would you mind provide us the micro-film. Just kidding.
    Mass-produce insofar as I can build lots of them in my basement! So we're not talking thousands, but hopefully hundreds.

    The knob and the lever are at the limits of what my injection machine will produce... I have to put all my weight on the lever to inject plastic into those, so I'm hoping to fit the pneumatic cylinder onto my injector to speed up the process and make it less tiring on my tiny arm muscles! I don't know yet if it will produce enough pressure, so will be doing some experimenting.
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  15. #12
    Supporting Member Kwings714's Avatar
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    Re: New Quadrant controls

    Are you using SolidWorks or Creo? I see you have components printed in 3D.
    Last edited by Kwings714; Feb-21-2019 at 22:00.
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  16. #13
    Supporting Member TWC_Sparky's Avatar
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    Re: New Quadrant controls

    Very nice, looking forward to when they are ready for some abuse.


    ~S~ Sparky
    [SIZE=3]MY RIG - Intel Core i7-7820X Skylake-X 8-Core 3.6 GHz LGA 2066 [ASRock Fatal1ty X299 Professional Gaming i9 LGA 2066 Intel X299 SATA 6Gb/s USB 3.1 USB 3.0 ATX Intel CORSAIR Vengeance LED 32GB (4 x 8GB) 288-Pin DDR4 SDRAM DDR4 3200/FONT]2-SAMSUNG 960 EVO M.2 250GB NVMe PCI-Express 3.0 x4 Internal Solid State Drive, SAMSUNG 850 EVO 2.5" 1TB SATA III 3D NAND Internal Solid State Drive, WDC 4TB WD40EZRZ-00GXCBO, Corsair Hydro Series H100i V2 Extreme Performance Water / Liquid CPU Cooler. 240mm, EVGA GeForce GTX 1080 Ti FTW3 GAMING, 11G-P4-6696-KR, 11GB GDDR5X, iCX Technology, EVGA SuperNOVA 1200 P2 220-P2-1200-X1 80+ PLATINUM 1200W Fully Modular, THRUSTMASTER THRODDLE HOTAS, VIRPRIL VPC MongoosT-50 BE Flightstick, MFG CROSSWIND PEDDALS,

  17. #14
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Quote Originally Posted by Kwings714 View Post
    Are you using SolidWorks or Creo? I see you have components printed in 3D.
    I originally designed everything using DesignSpark Mechanical, but I'm converting everything over to Fusion 360 for the CAM. Anything that gets 3-D printed I can still use DesignSpark, but to generate the toolpaths for cutting my molds on the CNC I use Fusion 360 CAM.
    I still like to do a lot of design work in DSM, because the push/pull architecture makes it easy to whip stuff out quick.
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  18. #15
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Large quadrant project is on hold for now, as I don't have the resources to produce all the parts yet. Still working on it as I have time.

    I Do however have a couple projects that are almost ready for sale or production.

    First is a USB switch box or switch panel that just gives you 36 digital joystick inputs. I have a bunch of boxes already built up... just need to make the enclosure bottom and print up some label blanks and they'll be ready to ship.

    IMG_20190827_172935059_compress96.jpg IMG_20190922_175142939_compress9.jpg

    Next should be ready in a few weeks... a USB mini-quadrant for those who don't have a lot of room on their desktop. Enclosure has been designed and tweaked, just laying out the PCB now. Will have to make a couple molds for levers and knobs.:

    SpaceClaim_2019-10-08_14-39-40.png kicad_2019-10-08_14-47-51.png kicad_2019-10-08_14-48-01.png
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  19. #16
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Update on mini-quadrant...

    Prototype PCBs will be here by Monday, waiting for enclosure master from Shapeways. Here are some parts for prototype assembly, form & fit, etc.

    kicad_2019-10-16_12-38-23.png MiniQuadrantPrototype.png
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    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  21. #17
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    PCBs came in, pretty much perfect, though next time I think I'll add some alternate pads for the elevator trim so I can offer a left-handed quadrant. Built up 10 boards... solder stencil was good, only had one solder bridge out of the 10 boards. I can actually assemble the SMT components onto the boards faster than my little reflow oven can run a cycle. I may convert this to an all through-hole assembly... since I have to solder all the switches anyway, why not do the same with the other components too? I can run it through a wave solder machine all in one pass, rather than do the SMT components and then the TH components.

    Got the chassis from Shapeways this morning. Everything fits as planned, so just need to some painting and sanding to get the finish just right, then I can pour a mold and start producing.

    IMG_20191022_143431106_compress72.jpg IMG_20191022_143603164_compress61.jpg
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    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  23. #18
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Windows 10 Pro 64-bit
    Intel Xeon 31230 @ 3.20GHz (4 cores - 8 threads)
    16GB RAM
    NVidia GeForce GTX1080 (Asus Rog Strix GTX 1080)
    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  25. #19
    TF Leadership RAF74_Buzzsaw's Avatar
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    Re: New Quadrant controls

    Facinating project Kendy.

  26. #20
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Almost done with chassis molds for the mini-quadrant.

    Working on a design for a radiator crank for the BF-109. Looks like the crank rotates 2 full turns, and my pots have a 260 degree range, so geared accordingly. Ready to start printing out parts to test:

    SpaceClaim_2019-11-17_17-24-13.png SpaceClaim_2019-11-17_17-24-35.png SpaceClaim_2019-11-17_17-25-05.png
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  28. #21
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Tweaking Radiator control to make sure everything meshes just right. I originally planned to use a roller skate bearing on the crank handle, but it seems to turn just fine without it.

    IMG_20191123_152906256_compress11.jpg


    Finished the mold for the Mini-Quadrant levers... pumped out a bunch in Polypropylene on the injection molder. Working on the mold for the chassis and the knobs.

    IMG_20191123_153009987_compress44.jpg
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  30. #22
    Team Fusion 69th_Zeb's Avatar
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    Re: New Quadrant controls

    Nice work. I have a set of those Harbor Freight calipers. Can't beat the price.
    What are you using to shoot the molds?

  31. #23
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Quote Originally Posted by 69th_Zeb View Post
    Nice work. I have a set of those Harbor Freight calipers. Can't beat the price.
    What are you using to shoot the molds?
    Chassis molds will be silicon rubber, as my injection molder can't handle that kind of volume...limited to 1 cubic inch of material. For small items I use a PM-150 from LNS Technologies that I have modified with a pneumatic cylinder.

    IMG_20191123_160547174_compress19.jpg IMG_20190517_163025237_compress29.jpg
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  33. #24
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Everything tweaked just so... a little touch-up on the housing, and ready to make molds for this assembly.

    IMG_20191129_111558207_compress99.jpg
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  35. #25
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Started producing some of the parts for the radiator crank. I made a bunch using a neutral colored resin, but they didn't take paint very well so dumped them and mixed up some OD colored resin. These came out a lot better. Have a couple more molds to make and then this will be available on Amazon.

    IMG_20191212_102720551_compress98.jpg
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    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

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  37. #26
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    All finished and installed in my cockpit. Works like a champ...went for a test flight, and it really increases the immersion. Cool to look down at the handle on the screen a see it follow my hand as it cranks. It may take me a few flights to get used to the placement of the control.

    IMG_20191214_173709609_compress50.jpg
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    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  38. #27
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Not happy with some of the stuff I've been molding, as it is too hard to maintain quality parts with silicon molds and liquid resin, so decided to take a step back and design a quadrant control that I can easily 3D print. This new quadrant can be dropped into any control panel and attached with a couple screws. All parts will be 3D printed, (except for the potentiometer, brake spring, and screws). I'll probably print it in black or dark gray PLA.

    IMG_20200321_160737338_compress91.jpg
    Windows 10 Pro 64-bit
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    16GB RAM
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    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  39. #28
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Just a little preview...printing up some parts now.

    IMG_20200327_153316728_compress9.jpg
    Windows 10 Pro 64-bit
    Intel Xeon 31230 @ 3.20GHz (4 cores - 8 threads)
    16GB RAM
    NVidia GeForce GTX1080 (Asus Rog Strix GTX 1080)
    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  40. #29
    Supporting Member Kendy for the State's Avatar
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    Re: New Quadrant controls

    Working on the brake spring to get the tension just right, and waiting on some connectors from China, and we'll be ready to go.

    IMG_20200330_001534753_compress69.jpg
    Windows 10 Pro 64-bit
    Intel Xeon 31230 @ 3.20GHz (4 cores - 8 threads)
    16GB RAM
    NVidia GeForce GTX1080 (Asus Rog Strix GTX 1080)
    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  41. Likes ATAG_Snapper liked this post
  42. #30
    Supporting Member Kendy for the State's Avatar
    Join Date
    Nov 2015
    Location
    Oak Island, NC
    Posts
    462
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    72.07 MB

    Re: New Quadrant controls

    Windows 10 Pro 64-bit
    Intel Xeon 31230 @ 3.20GHz (4 cores - 8 threads)
    16GB RAM
    NVidia GeForce GTX1080 (Asus Rog Strix GTX 1080)
    512GB SSD
    LG 4K 43" TV
    Gear-Falcon General Purpose Joystick Controller, Gear-Falcon Quadrant and Trim, Gear-Falcon BF-109 Water Radiator Crank

    "Find out what you don't do well, and then DON'T DO IT!" - Alf

  43. Likes ATAG_Highseas, ATAG_Snapper liked this post
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