I'm brand new to the board and to flight sims in general although I am a qualified private pilot with around 500 hours logged.
As well as flying my other interests include all things technical and I have designed and built a few different 3D printers (and two full size aeroplanes )
I have seen a couple of DIY linear actuator designs on the internet and fancied a go at designing and building my own. I've based my design around a body tube consisting of standard 110mm plastic waste pipe. I have created two 3D printed 'end caps' that hold the bearings, axle and pulley around which the HTD 8 timing belt loops. One side of the belt is attached to a 3D printed 'piston' that runs on the inside of the pipe on three 608 skateboard bearings. Affixed to the piston is the 16mm diameter ground rod that forms the moving end of the actuator and it exits the top end cap in the tube via a LM16UU linear bearing. Each end cap also houses a micro switch to act as a limit switch and the base end cap also has a 10 turn potentiometer driven by 3D printed gears, one of which is affixed to the bottom pulley, to allow for position feedback. Total movement is around 400mm but could easily be increased with a longer tube, rod and belt. The bottom pulley is driven via a second set of pulleys and belts (HTD 5)at a 5:1 ratio and motive power is from a 24V 200W scooter motor. The parts count was quite cheap at around £100 all in and that included the roll of 3D printer filament required to print the components. I printed them in PLA with a high infill and wall content. I'm aiming to use Sabretooth 2x32 motor drivers controlled by the BFF software via Kangaroo interfaces,
I'm am just about to assemble the first unit (i need 6 for my planned platform) in order to test it for speed, strength and accuracy. My initial design calcs aim for around 30Kgs for the actuator giving a total of 180Kgs for the Stewart platform max load. As I plan just a seat, pedals and joystick in conjunction with a VR headset that should be enough. Time will tell. I would welcome any feedback. If anyone wants a copy of my Sketchup file they are more than welcome.