Custom Braille Card Embosser V1 - Hand Operated

Embossing Device STLs

Example Customized Cylinder STLs

Sliced print profiles (.3mf)

CAD source: Fusion360 project file + STEP + OBJ (for remixers)

P01

Body Base

P02

Body Top

P03

Embosser Holder - A1

P04

Embosser Holder - A2

P05

Counter Holder - B1

P06

Counter Holder - B2

P07

Grip Extension Bottom

P08

Grip Extension Top

P09

Handle Connector

P10

Handle Grip

Primary Web Based:

Open braille-cylinder-stl-generator.vercel.app, follow Video #1 below, "Customizing braille, downloading STLs, 3D-print settings".

Backup OpenSCAD offline alternative:

The OpenSCAD customizer is the offline, power user, backup for anyone not wanting to, or not able to use the browser based tool.

Note: Card thickness must match the cylinder thickness setting used. For example, 0.3 mm cylinders with 0.3 mm card and 0.4 mm cylinders with 0.4 mm card.

Base preset:

High Quality (or any sub-0.2 mm layer-height profile)

Wall generator:

Arachne (not Classic) improves recessed dot accuracy

Seam control:

Highly recommended to use Seam Painting on the indicator letter and triangle area only, to keep the seam off the braille dots

Speeds (roughly half of Bambu Studio defaults):

initial layer 40, infill 75, outer wall 50, inner wall 75, small perimeters 40 (accelerations also halved)

Supports:

none

Brim:

none

Material:

basic PLA tested; PETG should also work with tuning

Measured: 

24.68 g, 8.14 m, ~$0.62 at $25/kg PLA, 3 h 5 min total

Note: If clean dots come out at default speed on your printer, keep the faster settings. If dots look fuzzy or under-extruded, slow the print as the first troubleshooting step.

Customizing braille, downloading STLs, 3D-print settings

Assembling the 3D-printed parts

Using the completed Custom Braille Embosser

1.

Sort the printed parts. Identify the two cylinders; the embossing cylinder has raised dots, the counter cylinder has recessed dots. Identify the matching holder pairs by the mark on the side: plus "+" (P03 + P04) goes with the embossing cylinder; minus "−" (P05 + P06) goes with the counter cylinder. Keep the two groups separate so they do not get mixed up.

2.

Test fit each cylinder into its matching holder pair. Slide the cylinder in only partway first. The fit should be snug but still removable. If it is too tight to pull back out, sand the tight surfaces lightly and try again. Once the fit feels right, push the cylinder fully home into both holder halves.

3.

Confirm the triangle indicator positions on each finished cylinder assembly. Every holder has triangles on the top, sides, and bottom. The embossing cylinder side triangles point RIGHT; the counter assembly's side triangles point LEFT. When the two assemblies are brought together the top and bottom triangles should point directly at each other, the side triangles should mirror each other, and the gear teeth should interlock cleanly.

4.

(Optional) Install the Grip Extension before adding the cylinders. Slide the top piece (P08) down over the Body Base (P01) from above. Set the bottom piece (P07) on a flat, solid surface, line up the base + top above it, and press down firmly until it clicks into place. Skip this step if you do not want the longer grip.

5.

Test fit the Body Top (P02). Snap it onto the Body Base once and remove it again to confirm it seats and releases cleanly. If it is hard to pull off, brace the lip of the lid against a solid surface and pull down to pop it off. Set the lid aside for now.

6.

Install both cylinder assemblies into the Body Base. Hold the two aligned cylinder assemblies in one hand, palm facing up and bring the Body Base over them with your other hand. Double check the orientation: embossing cylinder on the LEFT (X-shape on top); counter cylinder on the RIGHT. Slide the assemblies in gently. At about the halfway point they should stay put on their own. Re-check the triangle alignment once seated.

7.

Insert the Handle Connector (P09). Its X-shaped end drops into the matching X-shape on top of the embossing-cylinder holder (left side).

8.

Snap the Body Top (P02) back into place over the cylinders. Press straight down until it clicks.

9.

Snap the Handle Grip (P10) onto the Handle Connector. Press down until it clicks into place.

10.

Test the mechanism. Rotate the handle a couple of turns. It should feel a little stiff but not difficult. If rotation feels jammed or hard, pull the lid off and re-check the alignment (embossing left, counter right, triangles mirrored).

1.

Align the indicator triangles on both cylinders so they point directly at each other (starting position).

2.

Rotate the device so the rollers are horizontal.

3.

Drop a card of 0.3 mm or 0.4 mm between the rollers.

4.

Turn the handle forward about a half turn.

5.

Verify dots are embossing correctly

6.

Roll the card forward and backwards several times to fully emboss the dots

Note: To change the message, pull off the lid, swap in a new embossing cylinder, realign the triangles, and continue.

Dots flat topped or crushed  — Card thickness doesn't match the plate pair. Use the matching 0.3 mm or 0.4 mm pair.

Dots too shallow or missing — Cylinder print quality. Reprint cylinders using the Special Print Instructions above.

Card braille dot tears — Card too thin try using the 0.3 mm thickness setting.

Hard rotation — Cylinders misaligned. Remove the lid, realign triangles, embossing-left and counter-right.

Cylinders hard to swap — Use a small flathead screwdriver carefully to pry upwards.

Hardware: CERN-OHL-W v2

Documentation, photos, videos, written tutorials: CC BY-SA 4.0

Project software/scripts: GPL-3.0-or-later

Customizer software (deployed web app AND vendored OpenSCAD copy in this download): PolyForm Noncommercial 1.0.0 — free for personal, educational, and non-commercial use; commercial use is not permitted.

Note: Printables only allows a single license dropdown per listing. The closest umbrella match is CC BY-NC-SA 4.0. The per-component licenses above are the authoritative source.

Device designed by Brennen Johnston.

Plate generator code from the companion projects https://github.com/BrennenJohnston/braille-cylinder-stl-generator (web-based, primary) and https://braille-cylinder-stl-generator.vercel.app/ and https://github.com/BrennenJohnston/braille-cylinder-stl-generator-openscad (OpenSCAD, alternative), also by Brennen Johnston. 

Braille translation by the open-source Liblouis library.

Project made possible  with the support from the Washington Assistive Technology Act Program (WATAP) - a statewide program that helps Washingtonians of all ages and abilities make informed decisions about, and gain access to, assistive technology. Learn more: https://watap.org/

Project made possible  with the support from the University of Washington Center for Research and Education on Accessible Technology and Experiences (UW CREATE) - an interdisciplinary research center whose mission is to make technology accessible and to make the world accessible through technology. Learn more: https://create.uw.edu/

Documentation template by Makers Making Change / Neil Squire Society (CC BY-SA 4.0). (Coming Soon)

Related earlier braille project: Better Braille Alphabet Board