This remix of the awesome Split Flap Display of Morgan Manly has an additional 11 flaps with special characters.
The following special characters are added between the 9 and whitespace flaps:

' : ? ! . - / $ @ # %  

Alternative currency symbol € and ₤ flaps are also included.

‼️ I made a tool to easily create your own customised flaps. You can choose the specific characters (also other languages/alphabets), the font style and font size. Check it out here: [https://makerworld.com/en/models/1309545-split-flap-display-flap-customiser#profileId-1343574](https://makerworld.com/en/models/1309545-split-flap-display-flap-customiser#profileId-1343574)

If you'd like to customize the flaps/charset yourself, please update the SplitFlapModule::ExtendedChars[48] constant at the top of the file src/SplitFlapModule.cpp accordingly.

Home assistant

We've added support for Home Assistant via MQTT. It adds a text/command entity and a sensor (which the display publishes to what is currently displayed) 

Printing Instructions

There are two print profiles, one for the module enclosure (0.4 nozzle recommended) and one for the flaps (0.2 nozzle & smooth plate recommended)

For the best results I recommend to dial in the ironing (and shrinkage) parameters for your printer & filament if you haven't done so already

If you start fresh, print:

• [Enclosure] 
  • Plate 1 and 2 for every module you'd like to create 
  • The sandwich plates (Plate 3, one time per display)
  • The endplates (Plate 4, one time per display)
• [Flaps] 
  • Complete extended set (48 characters)

If you'd like to upgrade from the original model, print

• [Enclosure]
  • The housing and the flap drum 
  • The sandwich plates (Plate 3, one time per display)
  • The endplates (Plate 4, one time per display)
• [Flaps] 
  • Upgrade set (Plate 2)

Assembly Instructions

The BOM, Assembly instructions and wiring diagrams of the original model can be used, see here.
The latest firmware, which I'll be helping with development, can be found here: [https://github.com/jhoff/Split-Flap-Display](https://github.com/jhoff/Split-Flap-Display) 
 

My Alterations/Additions/Recommendations:

• Instead of wiring the esp32 directly to the first module I recommend adding the esp32 separately with a JST connector, something like this:
  
• The drum is split up so no supports are needed, resulting in cleaner flapholes (yes, that's a word) 
  In my case it snapped into place really tight but depending on the tolerances of your filament you might need to add a touch of glue.
  If the tolerances are too tight, there is also the full drum object on Plate 5 so you could easily split it in Bambu Studio with adjusted tolerances yourself.
• I've added a spot for a I2C multiplexer board TCA9548A. We're looking into multiple ways to extend the current 8 module limit in the firmware. With multiplexing it should be possible to control 64 modules and @jhoff is testing out driving 3 motors per PFC8575 IO expander module.
• Halfway through my third batch of 8 modules I had some issues with the tolerance of the main gear in relation to the motor cap/end-plate. Not sure if it was because of new spool of filament or the new Bambu Studio version (or the ‘spaghetti con clogs’ I had when I put in a wrong build plate) but if you also encounter this you might want to check out @jhoff's metal dowel mod.

• With the bigger drum, not only the ‘Extended Charset’ should be selected in the settings but also the magnet position should be changed to around 615 (this will be set automatically when selecting the extended charset in the next software update)

  

Discord

We've created a discord channel. If you have any questions about the build or if you have any ideas for new (firmware) features please let us know!  [https://discord.gg/qTkKP2STHe](https://discord.gg/qTkKP2STHe) 

Roadmap

Upcoming Firmware update:

• UX improvements and redesign