🙋♂️🙋♂️ Oh! oh! Pick me! pick me! ... I'll go next.
So over the years, I've posted various questions about this Wordle Wheel / Companion that I make and sell on my site, and thought I'd give everyone a little peek into how the sausage is made.
For anyone that isn't familiar, Wordle is a NYT daily puzzle where you have to guess a 5-letter word, using a system much like the old Mastermind game of yore. A friend once said, "hey, there's gotta be something you can do with your 3D printer to make it easier for someone to figure out the daily word", and the Wordle Wheel was born after a fair amount of head scratching and Fusion-fu.
It basically fits in the palm of your hand and has some nice ASMR clicking as you dial in the letters - Each wheel has 27 (26 letters + 1 blank for guessing) cogs with vinyl letters applied so you can dial in what you know and then spin the other wheels to get inspiration.
The pieces for this are primarily 3D printed, with the addition of an acrylic axel and the vinyl lettering
The arm assembly is printed in pieces in order to leverage the strength of layers and glued (Testers) to construct the assembly which is then glued in to the base


Of course, there are a number of 3D printed jigs and clamps that help me bring the whole thing together

I had dreamed of incorporating the letters into the 3D print of the wheels, but even with my H2D that doesn't seem feasible. The letters are only 4mm high and since they print on the side of the wheel as opposed to a surface, my tests haven't even gotten out of the slicer, since when I look at the tool paths, letters like "D" and "E" just become blobs. My other thought was to basically print a strip of just the cogs with the letters on the surface. Have them connected with a very thin (0.5 mm) base and then print plain disks and glue the strip of cogs wrapped around the edge of the disk. Not sure that will really work since the cogs still have some curvature on their base where they meet the wheel.
For now, the vinyl lettering works well and is distinct, visually. Over the years, I've sold over 300 of these and no one has come back with missing or falling off letters, so they must last pretty well. (family uses them as well on a regular basis). This is my busy season, so I've got 10 of these puppies lined up waiting for lettering.