Daniel, aka CNCDan, wasn’t seeking to revolutionize digital actuality. He simply needed a extra immersive sim racing expertise with out breaking the financial institution. His resolution? A completely 3D printed VR headset constructed with AliExpress elements, open supply software program and an limitless want to mod.
He began with a easy objective: make sim racing extra lifelike. Industrial VR headsets, even the entry degree ones, have been too costly and had too many options like hand monitoring he didn’t want. As an alternative of settling he determined to make use of his 3D printer and downside fixing abilities to create a headgear tailor-made to his wants. The result’s a tool with 2880×1440 decision, adjustable interpupillary distance (IPD) and in-built head monitoring, all for a tenth of the value of the mainstream choices. It’s not good however it reveals what’s doable when ingenuity meets willpower.
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The headset has two 2.9 inch sq. screens. Daniel searched AliExpress for prime decision shows earlier than deciding on these. They’re a compromise between readability and measurement. Bigger 3.8 inch OLED panels would have elevated the minimal IPD to 68mm, excluding too many individuals as the typical grownup IPD is round 63mm with a spread of 45-80mm. The two.9 inch screens are barely greater than 54mm vast and have a minimal IPD of 54mm so they’re appropriate for a wider vary of individuals. Daniel selected the cheaper 90Hz model over the costlier 120Hz one and solely later discovered that full decision solely runs at 60Hz which will be uneven in VR. However the shows are sharp sufficient for sim racing and show that low price parts can outperform expectations.
Lenses have been the subsequent problem, so he used his data of FPV drone headsets. Daniel thought of Fresnel lenses which are sometimes offered in workplace provide shops as magnifying sheets. Testing with a cellphone display screen confirmed a focal distance of round 60mm which is simply too huge for a slim design. A final minute discover on AliExpress modified every thing: lenses for Google Cardboard with a 45mm focal distance that supplied a extra compact choice. These lenses match into 3D printed “eye containers” made from matte black PLA to scale back reflections and supply a transparent view of the shows. They’re held in place by a twist-on retaining cap, which eliminates the necessity for glue, and makes changing them simple in the event that they get scratched.
Head monitoring is important for sim racing and Daniel used a GY-9250 IMU sensor with an Arduino Professional Micro. He closely relied on Relativty’s open-source SteamVR head monitoring driver, a mission so good it’s onerous to consider a 15 yr outdated began it. The software program handles roll, pitch and tilt – every thing you want for immersive driving – with out the complexity of positional monitoring. To maintain issues tidy Daniel designed a customized PCB however it’s optionally available if you happen to’re comfy soldering on to the Arduino. The setup requires a fast calibration through Arduino Studio to forestall drift however as soon as dialed in it tracks head actions easily and integrates seamlessly with SteamVR.
The headset’s physique is a symphony of 3D printed parts, every exactly deliberate for performance. The attention containers that maintain the screens and lenses slide alongside 145mm chrome steel rods for IPD adjustment, that are secured with M3 screws and thumb knobs for ease of utilization. The principle physique piece is printed nose-side as much as eradicate help considerations and is held collectively by M3 threaded inserts. The HDMI driver and head tracker are housed within the entrance cowl, which has a show splitter board taped in place. Daniel’s consideration to element extends to the tiny issues, akin to routing energy by the Arduino to save lots of additional cords and utilizing a folding FFC cable to maintain the inside clear.
Daniel used an HTC Vive face pad that was cheap and readily accessible, with self-adhesive Velcro for easy substitute. The pinnacle strap is constructed of 25mm strapping and 3D printed PLA buckles, and it’s surprisingly sturdy. The rear plate is printed in versatile TPE and fixes the strap with none inside helps; merely pause the print and insert the fabric. The top result’s a headset that’s comfy for prolonged racing classes, however Daniel acknowledges that the face plate could not match each face form.
What makes this mission so accessible? Daniel has uploaded all of his information to GitHub, together with 3D fashions and software program directions. So, when you have a 3D printer and sufficient persistence, you can also make your individual.
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