Build Instructions 3D Printed
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How to Build the Dementia Friendly Music Player Using a 3D Printed Case 7 April 2019, http://DementiaMusicPlayer.org, Ross Porter rosswesleyporter@gmail.com My Dad could not operate normal music players. But he could operate music player like this because it operates like a familiar two-knob radio. I was inspired by the documentary Alive Inside which shows the profound joy felt by some people with dementia when listening to their favorite music. I designed the insides and Trey Bagley designed the 3D printed case shown here. It’s easier than you think to make one. Everything is open source. This document contains all the information you need. Good project for kids. A 13 year old can do this with minimal assistance. Younger kids with more assistance. 3D printed case designed by Trey Bagley Parts cost Music cost Build time Parts source Soldering? 3D printer needed? 3D printing time With a friend? Beverage? ~$60 + tax + shipping Minimal as you should use the recipient’s existing music collection About two hours, once you have the parts & music All parts can be mail ordered, links below No Yes, or work with a friend that has a 3D printer About 24 hours Good idea, especially if your friend has the basic tools required I recommend a hoppy IPA while you are assembling 1 1 Preview of the build steps 1) Order parts 2) 3D print pieces 3) Stain the pieces (optional) 4) Assemble recipient’s favorite music 5) Copy software to micro SD card 6) Collect the parts & pieces 7) Add Pi 8) Install front panel components 9) Glue it 10) Wire it 11) Screw on back 12) Enjoy! 2 2 No warranty USE THESE DQMUSICBOX PLANS AND SYSTEM AT YOUR OWN RISK. THE DQMUSICBOX PLANS ARE PROVIDED AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE ENTIRE RISK AS TO THE QUALITY AND PERFORMANCE OF THE PLANS AND SYSTEM IS WITH YOU. SHOULD THE PLANS OR SYSTEM PROVE DEFECTIVE, YOU ASSUME THE COST OF ALL NECESSARY SERVICING, REPAIR OR CORRECTION. IN NO EVENT WILL ANY PARTY BE LIABLE TO YOU FOR DAMAGES, INCLUDING ANY GENERAL, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE THE PLANS OR SYSTEM. 3 Acknowledgements People were very generous with their time, and I really enjoyed the experience. This is certainly an incomplete list: Trey Bagley, Alex & Mike & others at Ada’s, the super helpful crew at Seattle Makers, neighbor Randy, Stephen Christopher Phillips, Bob Rathbone, Stephen Rusk, Graham Hill, support at Ponoko, and my son. 4 What DQMusicBox does 4.1 For the person with dementia Name Start song Change song Change volume Pause Description & implementation Turning either of the knobs will start music playing. Turn the songs knob. Turn the volume knob. Tap the volume knob. Note that this also happens automatically – music pauses if there are no knob events in one hour. 4.2 For you Name Shut down Reboot Add/remove music Description & implementation Pull the power plug or long hold (15-30 seconds) on the volume knob. Pull the power plug and re-insert or long hold (15-30 seconds) on the songs knob. By adding/removing files on the USB memory stick. 3 5 Order the parts You will be ordering these parts: 4 5.1 Order the parts Item Supplier Cost (2018) Notes & Alternatives Raspberry Pi 1 A+ single board computer Newark $18.00 Power supply Newark $5.99 This is the US model. Any micro USB 2A or better supply will do. Female-female jumper wires Newark $3.56 Or buy Amazon B01L5ULRUA Panel mount 3.5mm headphone jack Newark $2.69 Or buy Amazon B004JX64FE M2.5 standoffs (screws) – 8 of them Newark $3.84 Or by Amazon B06XXV8RTR Micro SD card 32GB Amazon $5.99 Any brand name micro SD card that is 8GB or larger will do. USB thumb drive 16GB Amazon $6.50 While nearly any USB thumb drive will work, I recommend one that is physically tiny so it doesn't protrude much from the case. Audio cable Amazon $5.88 Or find a short audio cable with a right angle bend. #4 x 5/8” flat head wood screws (5 screws) eBay $1.49 KY-016 indicator LED (note shipping time) eBay $1.62 Or buy at your local hardware store The linked seller ships from China, takes 2-3 weeks. Or order as one piece of this kit - Amazon B013UL6LFS, which will arrive in a few days (assuming you live in the US). KY-040 rotary encoders (knobs) eBay $6.36 Or buy Amazon B074TJ8RSX. TOTAL $62.12 Tested with a Raspberry Pi 1A+, 2B, 3A+, 3B, 3B+. Do not use Pi Zero. Prices will vary. Does not include tax, shipping. 5.2 About headphones Item The recipient’s existing headphone Monoprice On-Ear headphones Monoprice Over-the-Ear headphones Other Cost $0.00 $10.99 $15.99 Notes and alternatives The best headphones are the headphones that the recipient is already used to. Very good sound. Amazing sound. My musician son rates the sound as better than the ever-popular Sony MDR7506 headphones. Look for high sensitivity headphones, as the Pi’s output is a bit weak. 5 5.3 Tools & supplies You probably have some of these tools & supplies. If you don’t, you have a spouse or child or friend that does. This project is exactly the sort of thing that a friend would be happy to help you with. Link to order item Elmer’s wood glue 3/16th wrench or nut driver SD card reader/writer Painter’s tape Light blocking tape or sticker PLA wood filament (optional) Wood stain (optional) Raspberry Pi 3 (optional) Notes & alternatives Any wood glue will do Or needle-nosed pliers. Or really strong fingers Your computer may have an SD card reader/writer. If not, you probably have a friend that does. Or order a USB SDcard reader for your computer. Any tape that comes off easily will do. Painter’s tape is great. Regular masking tape is probably fine too. I haven’t tried Scotch tape. The unit’s LED is quite bright, so I prefer to block some of the light. You can use the tape above. Or order light blocking stickers such as B009WSJNCW. This document assumes that you have a 3D printer, or you have a friend with a 3D printer. So you already have some regular PLA filament. I chose to use a PLA wood filament, specifically Monoprice PLA wood filament. If you print with PLA wood filament, you can optionally apply wood stain. I used a pre-stain, a stain, and a protective finish. I went to the local hardware store and purchased what they recommended: Minwax Pre-Stain Wood Conditioner, Minwax Wood Finish Red Mahogany 225, Minwax Polycrylic Protective Finish. This is in addition to the Pi that goes in the player. This is a completely optional step. If you are nerd like me, or you have nerdly friend, see details in the appendix 1. 6 6 3D print pieces The key assumption is that you have a 3D printer, or you have a friend with a 3D printer. Thus, this document is not intended as an introduction to 3D printing. You will be printing the pieces that you see below. You should print in the orientation that you see below i.e. flat side down. On my basic 3D printer, the total print time was about 18 hours. 3D printed case designed by Trey Bagley 6.1 General instructions 1. 2. Download the stl files from Github. 3D print the files. 6.2 My experience Trey Bagley designed the case. I think he did a great job. But I’m a novice at 3D printing. Nonetheless here is what I did, and I’m happy with the result: • • Monoprice Maker Select v2 3D printer Monoprice PLA wood filament 7 • • • Cura slicing software Key settings o Layer height: 0.3mm o Initial layer height: 0.3mm o Wall thickness: 0.8mm o Top/bottom thickness: 0.8mm o Infill: 10% o Print temp: 188C (this low temperature reduced stringing issues) o Build plate temp: 50C o Diameter: 1.75mm o Flow: 100% o Enable retraction: yes o Retraction distance: 10mm o Retraction speed: 60mm/sec o Print speed: 45mm/sec o Infill speed: 50mm/sec o Travel speed: 120mm/sec o Initial layer speed: 5mm/sec o Enable print cooling: yes o Fan speed: 100% o Minimum layer time: 5 sec o Print sequence: all at once Post printing o My prints came out fairly clean, but I did use a tiny knife to extract extraneous strands from the lettering. 8 7 Stain the pieces (optional) This step is optional. I wanted to make something that seems familiar to someone with dementia i.e. make something that looks very much like a radio from the 1930s. These antique radios are made of wood and generally dark stained. Thus, I chose to print with a wood PLA filament and stain the print. You could choose to print with regular PLA filament. Or print with wood PLA but not stain it. Here is the before and after of staining the front face: I’m not a woodworker. Nonetheless, this is the process that I used: 1. 2. 3. 4. Sand the parts with a fine grit sandpaper. Apply Minwax Pre-Stain Wood Conditioner, let dry. Or a similar product. Minwax is what my neighborhood hardware store has… Apply Minwax Wood Finish, Red Mahogany 225. I applied a thin even coat. Minwax suggests waiting 15 minutes then wiping off the excess stain. I found this removed too much of the stain. So I didn’t do any wiping off and just let it dry overnight. Apply Minwax Polycrylic Protective Finish, let dry. 9 8 Assemble the personalized collection of music 8.1 Choosing the music – go for familiar favorites This is the most important step. The personalized (familiar) music is the fundamental magic. You don’t need much music, perhaps 6-10 albums. But only familiar favorites. In my case, my Mom mailed me my Dad’s favorite CDs. It will take two weeks for the parts above to arrive, so you have time to do this well. Though it is easy to change the set of music later. 8.2 Put the music on the USB memory stick Organize the digitized music into folders on the USB memory stick, one folder per album. MP3, iTunes, and FLAC files are supported i.e. files with extensions .mp3, .m4a, .flac. In the end, you should have a set of folders that looks something like this: 9 Prepare the micro-SD memory card I prepared a disk image for you. It has all the required software. Your job is to download this disk image and then write it to the micro-SD card. The steps: 1. Install Etcher on your PC or Mac or Linux computer. Win32 Disk Imager also works. 2. Download the Dementia Friendly Music Player disk image. 10 3. Confirm download – “Download anyway” 4. Put the micro-SD memory card into the SD card adapter that it came with i.e. put the tiny card into the larger card. 5. Put the SD card adapter into the SD reader/writer in your computer. 6. Start Etcher, instruct it to write the image file to the SD card: 7. Wait for the writing to complete, ~10 minutes. This would be a good time to make a sandwich. 11 10 Collect the parts and pieces You should now have the following: 12 11 Add Pi 11.1 Put the MicroSD card and the USB drive into the Pi 13 11.2 Mount the Pi Using the standoffs, mount the Pi in the body piece: 14 12 Install front panel components Install the two rotary encoders (knobs), the LED, and the headphone jack. The rotary encoders need to be screwed in as far as they will go, or the button press won’t work – test the rotary encoders to make sure they rebound from a button press. 15 13 Apply glue Apply glue to the front of the body piece: 16 14 Glue on the face Glue on the face, using painter’s tape to clamp: 17 CLK DT SW + GND 2 5v Power B G R 1 3v3 Power 8 GPIO 14 (TXD) 4 5v Power 7 GPIO 4 (GPCLKO) 10 GPIO 15 (RXD) 3 GPIO 2 (SDA) 9 Ground 12 GPIO 18 (PCM_C) 6 Ground 11 GPIO 17 14 Ground 5 GPIO 3 (SCL) 13 GPIO 27 (PCM_D) 16 GPIO 23 18 GPIO 24 18 Songs knob (rotary encoder) On/off indicator LED Volume knob (rotary encoder) 15 GPIO 22 17 3v3 power 20 Ground 28 ID_SC 19 GPIO 10 (MOSI) 27 ID_SD 30 Ground 22 GPIO 25 29 GPIO 5 32 GPIO 12 21 GPIO 9 (MISO) 31 GPIO 6 34 Ground 24 GPIO 8 (CE0) 33 GPIO 13 36 GPIO 16 23 GPIO 11 (SCKL) 35 GPIO 19 (MISO) 38 GPIO 20 (MOSI) 26 GPIO 7 (CE1) 37 GPIO 26 40 GPIO 21 (SCLK) 25 Ground 38 Ground CLK DT SW + GND 15 Wire it 15.1 Wire the knobs & LED Attach wires from the knobs and the LED to the Raspberry Pi as per the diagram and photos below. No soldering required – just press the wires into place. This is where most build errors happen, so please carefully check your work. The result should be as you see it below. The front of the LED should be flush with the front of the face. If the LED is a bit loose, just use some glue. 19 15.2 Add the audio cable The audio cable goes from the back of the Pi to back of the front panel’s headphone jack: 20 16 Screw on the back 21 17 Put the knobs on and enjoy! If the knobs don’t easily slide on the metal shafts, just heat the knobs up with a heat gun or hair dryer or (last resort) boiling water. You can also put some grease or cooking oil on the metal shafts. 22 17.1 Test it Now that you have assembled everything, it is time to test. Test Light 20sec after power on Start song Change song Change volume Pause Unpause Description & Expectation The indicator LED turns on when DQMusicBox is ready to play music, which is generally about 15 seconds after power on. Turning either of the knobs will start music playing. Turn the songs knob. If you go forward and backward through the song list as expected, then all is well. Turn the volume knob. If the volume goes up and down as expected, then all is well. Tap the volume knob, song should pause. Tap the songs knob, this should also pause the song. Tap a knob 17.2 If one or both knows do the opposite of what you expect Once assembled, you may find your knobs doing the opposite of what you expect e.g. a clockwise turn decreases the volume. This is because there are two kinds of rotary encoders out there. Happy, the fix is easy, just switch the orange and yellow wires on the misbehaving knob(s) (don’t touch the Pi itself): 23 17.3 Tape instructions Print this page and tape the instructions in the box below to the bottom of your new DQMusicBox: To create personalized music Organize the music on your computer One folder per album. Use MP3 files, must have .mp3 file extension. Or iTunes files (.m4a). Or FLAC files (.flac). Optionally, use folder names prefixes to specify the play order e.g. A_, B_ Copy the music to the USB thumb drive 1. Unplug your DQMusicBox. 2. Remove the USB thumb drive and place in your computer. 3. Copy music files from your computer to the USB thumb drive. 4. Put the USB thumb drive back in the DQMusicBox. 5. Plug in your DQMusicBox. 17.4 Congratulations Congratulations! You should have a fully functional DQMusicBox. 17.5 Let me know how it went I’d love to hear how your build process went and if it was useful for the recipient. rosswesleyporter@gmail.com 24 18 Appendix 1: Change log v1, November 2015 v2, September 2016 v3, January 2017 v4, May 2017 v4.01, 25 June 2017 v4.01_1, 20 July 2017 v4.01_2, 11 August 2017 v4.01_3, 12 August 2017 v4.01_4, 12 August 2017 v4.01_5, 14 October 2017 v4.01_6, 26 February 2018 v4.1, 7 April 2018 v4.1_1, 23 April 2018 V4.1_1, 6 May 2018 27 January 2019 v4.2, 1 March 2019 v4.2, 7 April 2019 Original release • Changed music storage from a micro-SD memory card to a conventional USB memory stick. • Changed the base Operating System from full Raspbian to DietPi – much smaller, so faster to boot, and less to go wrong. • Changed from USB audio to Pi built-in audio, including a firmware update for excellent audio quality. • Switched to bamboo for durability and use of standoffs. • Switched to Pi A+ to lower cost. • Made USB thumb drive externally accessible, to make it easier for the caregiver to organize music. • Minor edits. • Minor edits. • Added links for ordering parts in the UK. • Added detailed instructions for write protecting a micro-SD card. • Minor edits • Minor edits • Edited text and updated photographs to reflect the change from an HDD-style LED to a KY-016 LED module. • Updated the links for purchasing the parts. No changes to the parts themselves, just the links. • Minor change to the instructions, noting how the build can be accomplished in one sitting, if desired. • Reflects that the software has been updated to support the new Raspberry Pi 3 B+. No new software features. • Updated to reflect the new bamboo case design. • Adapted the existing instructions to match the new 3D printed case design. • Noted support for the Raspberry Pi 3A+. • Switched to pmount for USB drive auto mounting. • Removed instructions for write protecting the SD card – rarely used and may cause certain rare problems 25
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