CAD designer for 3D-Printable Electronic Card Game Wearable

Mechanical Product Designer for 3D-Printable Electronic Card-Game Wearable I am looking for an experienced mechanical/product designer or electromechanical CAD engineer to design a full-size, functional, 3D-printable wearable card-game device inspired by the general form and folding behavior of the Battle City-era Yu-Gi-Oh! Duel Disk. This is a personal hobby project. I understand that Yu-Gi-Oh!, Duel Disks, and their associated fictional designs are third-party intellectual property. I am commissioning original CAD, mechanical design, and engineering work for my personal device and would like ownership of the original files/work created for this commission, subject to those underlying third-party rights. This is intended to become a working electromechanical prototype, not simply a cosplay prop or decorative STL. The final system is expected to incorporate NFC card identification, optical/IR card sensing, distributed custom PCBs, servo-actuated mechanisms, spring-loaded mechanisms, a rechargeable battery, display, physical buttons, sound feedback, LEDs, and communication with an external game server. I am looking for someone comfortable designing a functional product that can be iteratively prototyped and revised. Overall design direction The device should visually resemble a modern evolution of the classic Battle City Duel Disk: circular/compact central body mounted to the forearm folding blade assembly relatively thin, angular profile mechanical sections that integrate cleanly when stowed modern Yu-Gi-Oh! field functionality when deployed I do not want a bulky generic sci-fi console with cards attached to it. When inactive, the device should retain a relatively compact Battle City-style silhouette. When activated, the blade and additional zones should deploy into a functional modern playing field. The design should prioritize: wearability durability mechanical reliability repairability/serviceability electronics integration modularity realistic FDM manufacturing reasonable weight distribution future prototype revisions Card and sleeve requirements Yu-Gi-Oh! cards measure approximately 59 × 86 mm. For this project, cards will normally be double sleeved. The intended setup is: Yu-Gi-Oh! card → Dragon Shield Japanese Perfect Fit inner sleeve → thin NFC tag associated with the card → opaque-backed Dragon Shield Japanese-size outer sleeve The NFC tag should therefore be hidden during normal use. The final slot/card-zone dimensions should not be designed solely around the nominal 59 × 86 mm card dimensions. I will provide physical measurements of a completed double-sleeved and NFC-tagged reference card once the hardware arrives and the exact configuration has been tested. Card slots should therefore be parametric or reasonably easy to adjust during development. All card-contacting geometry should avoid scraping, bending, pinching, or damaging sleeves. Main Monster Zones The blade must contain exactly five Main Monster Zones. These should be flat or very shallow recessed card beds rather than insertion slots. They must accommodate: portrait / Attack Position landscape / Defense Position face-up monsters face-down monsters Each Monster Zone should include provisions underneath for three optical/IR sensors, with the current intent being to infer: zone occupied/unoccupied portrait vs. landscape orientation invalid/partial placement The exact sensor model and positioning will be determined experimentally. Ideally, sensors should be mounted on small removable PCBs or other serviceable modules below each card bed. Card beds should also have appropriate finger access so cards can be removed easily. Spell/Trap Zones There must be exactly five Spell/Trap Zones. I want these implemented as partial-insertion card slots, similar in concept to the Spell/Trap holders seen on older Battle City and 5D’s-style Duel Disks. The cards should slide partially into the blade while remaining mostly visible and easy to remove. These slots should: retain double-sleeved cards during arm movement avoid gripping them tightly enough to damage sleeves have smooth/chamfered entry surfaces integrate visually into the blade avoid looking like five separate boxes attached to the outside Each Spell/Trap Zone should also include sensor provisions. I would like the electronics to eventually differentiate: empty face-down / Set face-up / activated The current plan is to combine occupancy sensing with optical/color/reflectance sensing. Because the outer sleeves will have an opaque colored back and a transparent front, it may be possible to distinguish a consistent sleeve-back color from the visible face of a Spell/Trap card. The exact optical hardware is not finalized, so the sensor geometry should remain adjustable during prototyping. Deployable Field Zone There should be one dedicated Field Zone, but I do not want it permanently exposed as another flat zone on the blade. Instead, I would like the Field Zone integrated into one side of the central Duel Disk body as a retractable/pop-out card holder. When stowed, the Field Zone should visually integrate into the shell rather than looking like an external tray permanently attached to it. A desired interaction would be: Field Spell scanned on NFC reader → Field Zone deploys → user inserts/places Field Spell → Field Zone is retracted → closed-position detection confirms/activates the Field Spell In other words, physically retracting the Field Zone could act as an activation/confirmation gesture. The final software behavior is not fixed, so the Field Zone should also be able to operate via manual button or server commands. Desired mechanical features include: deployment from one side of the central body sturdy card support positive fully-open position positive fully-closed position microswitch, Hall sensor, or similar position feedback servo-powered or otherwise controlled retraction optional spring-assisted deployment manual override in case of power failure serviceable actuator occupancy/card-presence sensing if practical sufficient clearance so the card cannot be damaged during movement The Field Spell should remain visibly presented while the Field Zone is deployed. Ideally, the mechanism would prevent retraction if the card is badly misaligned. Extra Monster Zones There must be two deployable Extra Monster Zones. These should normally be hidden/stowed and should deploy outward from the front edge of the blade, rather than backward behind it. Their deployed position should be roughly in front of the central portion of the five Main Monster Zones. I do not want thin/flimsy hinged flaps. They should look and feel like substantial structural extensions of the blade. Preferred mechanism The desired concept is: spring-assisted deployment + powered servo retraction Deployment: Extra Monster Zone is held inside/stowed by a mechanical latch. Latch releases. Spring/torsion mechanism deploys the zone. Zone reaches a positive mechanical stop and becomes structurally supported. Retraction: Servo or compact actuator retracts the zone. Zone returns to the stowed position. Mechanical latch automatically re-engages. Servo should not need to continuously hold the zone closed. Each mechanism should ideally include: positive deployed stop positive stowed stop position sensing replaceable/serviceable spring accessible servo manual override/retraction if power fails The two Extra Monster Zones will also require Monster Zone-style card/orientation sensors. Central NFC scanning orb The central body should feature a visually prominent NFC scanning orb/pad. This is intended to be the primary card-identification interface. The desired appearance is a relatively flat, translucent/frosted acrylic or polycarbonate lens with a lighting element underneath. An off-the-shelf PN532 NFC reader will be used during early prototyping. Normal operation will be approximately: card tapped on NFC orb → card identified → device waits for placement → player places card into physical zone → zone sensors determine location/state The NFC scanner should therefore: be easy to reach repeatedly minimize material thickness between antenna and card avoid nearby metal where possible avoid batteries or major conductive structures immediately behind the antenna provide removable access to the NFC hardware allow room for RGB/status illumination potentially use a removable diffuser/lens The PN532 may remain a separate module even after other electronics are migrated to custom PCBs, depending on antenna testing. Main Deck holder The Main Deck should use a side-loading magazine/holster, inspired by the general concept used on the Battle City Duel Disk. I do not want the Main Deck sitting in a recessed tray on top of the central body. The deck should insert into the side of the device and remain securely retained while worn. It should accommodate a full double-sleeved Main Deck. Exact finished stack thickness will be provided after physical measurements. The holder should provide: easy access for drawing cards enough retention that the deck cannot fall out tolerance for different deck thicknesses minimal pressure on sleeves Possible retention ideas could include: spring-loaded follower compliant retention plate adjustable stop soft friction insert low-friction retaining lip I am open to designer recommendations. Extra Deck holder The Extra Deck should use a similar side-loading magazine/slot, integrated elsewhere around the central body. It should visually match the Main Deck holder but accommodate the smaller Extra Deck stack. Exact dimensions will again be based on physical double-sleeved cards. Graveyard and Banished zones I am interested in integrating the Graveyard and Banished piles as retractable trays/drawers rather than permanently exposed recessed areas. A possible interaction would be: game determines card is going to Graveyard → Graveyard tray deploys → user places card → tray retracts The same concept may be used for the Banished pile. Manual deployment from the control panel should also remain possible. These trays should hold growing stacks of double-sleeved cards. They do not need to mechanically feed individual cards. Potential actuation could include: servo-driven trays spring-assisted deployment with powered retraction another compact mechanical solution They should include: positive open/closed positions position sensing manual override easy access if cards become misaligned serviceable motors/springs enough capacity for a reasonable game-state stack If fully motorized trays prove too bulky or complex, I am open to a spring-assisted pop-out/manual-reset alternative. Display The central body should include a clearly visible display. The primary purpose is Life Point tracking, but it may also display: scanned card confirmation menus selected game/ruleset connection status battery level warnings mechanism state The exact screen has not yet been selected. A small OLED or TFT is likely. The mechanical design should therefore reserve an appropriately located display bay/mount that can be refined once the final screen is chosen. Physical controls The central body should include an easily reachable physical-control cluster. I have already purchased the prototype switches and would like the mechanical design to accommodate them unless testing later indicates that a different switch is preferable. The current switches are: Low Voltage Labs momentary tactile push buttons 12 mm × 12 mm × 7 mm Through-hole PCB mounting Colored actuator/cap options: red, blue, green, and yellow 20-switch set These are intended to be mounted to a removable UI/control PCB rather than individually wired into the enclosure. The final PCB layout can be designed around their through-hole footprint once physical samples are measured. Because these switches already include colored push surfaces, custom printed caps are not required by default. The enclosure may expose the existing colored actuator surfaces directly through appropriately sized openings. However, if improved ergonomics, visual integration, or custom symbols are desired, the CAD should allow optional removable button-cap overlays to be added later without requiring redesign of the UI PCB. Potential controls include: Confirm Back/Cancel Mode/Menu Life Point increase/decrease Field Zone control Graveyard/Banished deployment Extra Monster Zone controls game/ruleset selection contextual actions Exact button assignments and quantity are not finalized and should remain reasonably configurable during early development. The device will also use a physical on/off rocker switch as the master power control. This should be mounted somewhere accessible but recessed/protected sufficiently that it cannot easily be switched off accidentally while the device is worn. Audio A piezo buzzer module has been purchased for the prototype. It may be used for: NFC confirmation placement confirmation errors menu sounds mechanism warnings other feedback The final housing should include either a mounting location for a separate buzzer or provision for one on the UI PCB. There should be an appropriate sound opening/grille so it is not completely muffled by the enclosure. Battery The currently selected prototype battery is: 3.7 V single-cell LiPo 2000 mAh approximately 60 × 36 × 7 mm The final battery bay should provide additional clearance rather than fitting those dimensions exactly. An initial envelope around approximately 65 × 41 × 10–12 mm may be appropriate, subject to physical testing. The battery must: remain removable not be tightly compressed by rigid printed parts have space for wiring/connector use soft padding/retention where appropriate remain close to the forearm/central body for weight distribution A serviceable battery cover is preferred. Prototype ESP32 vs. final electronics Initial electronics testing will use an ESP32 development board. The development board should be treated as a prototype platform only, not as the final mechanical constraint. The finished device will likely use a custom central controller PCB containing an ESP32 module or similar microcontroller. Please do not optimize the complete final housing specifically around the current ESP32 development-board dimensions. Instead, the central body should provide a flexible electronics bay that can accept custom PCB revisions. Distributed custom PCB architecture The final Duel Disk will likely contain multiple custom PCBs rather than one large central board. Likely architecture: Central controller/power PCB Located in the central body. Potential functions: ESP32 module communications power management/regulation battery monitoring data-bus interface primary system connectors UI PCB Potential functions: tactile buttons display connector buzzer status LEDs scan-orb lighting Blade controller/sensor PCBs Located within individual blade sections. Potential functions: reading nearby IR/optical sensors sensor calibration reporting zone state to central controller Actuator electronics Potential functions: Extra Monster Zone servos Field Zone mechanism Graveyard/Banished mechanisms position sensors actuator-power distribution The exact number and dimensions of PCBs are not finalized. The mechanical design should therefore favor modular board mounting, removable covers, accessible connectors, and adaptable electronics trays. Wiring through folding joints Because the blade contains moving/folding sections, I do not want dozens of individual sensor wires routed through every hinge. Instead, local blade electronics should collect sensor information and communicate with the main controller using a low-wire-count bus. A future implementation may use something such as CAN bus between boards. A typical hinge harness could therefore contain approximately: power ground differential data pair possibly separate actuator power if required The exact protocol is not finalized, but the mechanical architecture should assume distributed electronics. The hinge design must account for wiring from the beginning. Do not design the hinge completely and then attempt to route wires through leftover space. Each wired moving joint should provide: dedicated protected cable path controlled bend radius adequate service loop strain relief smooth edges clearance from hinge pins/gears/latches no repeated tight crease at one point replaceable harness removable access panel Flexible fine-stranded wire and locking connectors will likely be used. A future revision could potentially use flex PCBs, but the first design should assume conventional replaceable cable harnesses. Logic and actuator power The device will contain both low-power/sensitive electronics and servo/motor loads. The design should allow reasonable separation between: Logic/sensor systems ESP32 NFC optical sensors inter-board communications display UI and: Actuator systems servos Field Zone Extra Monster Zones Graveyard/Banished trays These may share the main battery/common ground while using separate regulation/distribution. The mechanical design should allow appropriate routing and placement for both. Sensor modularity Where practical, sensors should live on removable small PCB assemblies rather than being glued individually into the shell. For example, one reusable Monster Zone PCB may eventually contain the three sensors required for one zone. Copies could then be installed in: 5 Main Monster Zones 2 Extra Monster Zones Spell/Trap sensor modules may similarly use a repeatable design. This should make replacement and future revisions much easier. Mechanical serviceability I want the device to be repairable rather than permanently sealed. The following components should ideally be replaceable without destroying major printed parts: NFC reader display UI/button PCB battery main controller PCB blade controller boards sensor modules servos springs wiring harnesses Field Zone mechanism Extra Monster Zone mechanisms Graveyard/Banished mechanisms major hinges/latches Frequently serviced areas should preferably use machine screws and heat-set threaded inserts. Additive manufacturing — FDM and resin The project has access to both FDM and resin/MSLA 3D printing. Structural components should primarily be designed for consumer/prosumer FDM printing. Likely materials include PETG and ASA, with PLA potentially used for early prototypes. The expected FDM build volume is approximately: 256 × 256 × 256 mm I also own an Elegoo Mars 2 Pro MSLA resin printer. Its available build volume is approximately: 129 × 80 × 160 mm Resin printing may therefore be intentionally incorporated into the design for suitable smaller components where higher resolution or smoother finish is useful. Good resin-printing candidates may include: decorative trim and inserts display bezels NFC-orb bezel/detail components small icons/emblems fine cosmetic components optional button-cap overlays small sensor brackets indicator/light-pipe components small precision covers or guides FDM should generally remain the preferred process for: main shell structures blade sections forearm mounting structure card trays and magazines large mechanism bodies PCB trays structural brackets parts subjected to substantial impact/load Standard photopolymer resin should not automatically be assumed suitable for highly loaded, repeatedly flexing, impact-prone, or spring-loaded components. If a small functional component would benefit from resin printing, please specify whether a tough/ABS-like/engineering resin would be recommended rather than standard hobby resin. Major hinges, actuator pivots, spring mechanisms, latch structures, and other high-cycle/load-bearing elements should generally use appropriately oriented FDM components and/or conventional metal hardware unless there is a compelling reason otherwise. The design may use a hybrid construction approach in which structural FDM parts contain locating features or recesses for separately printed high-detail resin components. Parts should be designed with the available printer envelopes in mind rather than requiring arbitrary scaling or post-design segmentation. Weight and ergonomics This is intended to be worn on the forearm. Weight distribution is important. Heavier parts such as: battery primary electronics major actuators where practical display should remain near the forearm/central body. The blade should remain as lightweight as reasonably possible. The arm mounting system should: distribute weight comfortably support adjustable straps permit padding remain removable/serviceable not obstruct access to electronics unnecessarily I am open to recommendations regarding realistic overall weight and dimensions. Future extensibility The first intended game is Yu-Gi-Oh!, but the underlying electronics may eventually support other physical/digital card games. I do not need the physical card zones redesigned for multiple formats at this stage, but the electronics packaging and PCB architecture should avoid unnecessary limitations where reasonable. The final controller may receive different game/control profiles from an external server. Preferred development process I would strongly prefer this project be developed in milestones, not as one monolithic CAD delivery. A possible development sequence is: Overall concept/layout proportions field layout folding arrangement central body basic ergonomics High-risk mechanical systems blade folding mechanism Extra Monster Zone spring deployment/servo retraction deployable Field Zone Main Deck magazine Graveyard/Banished tray concept hinge/cable routing Electronics integration NFC orb battery UI/display modular PCB locations sensor modules actuators wiring Detailed full assembly Prototype-print revisions tolerances fit strength mechanism refinement physical electronics measurements Final documentation and files I expect physical prototyping to reveal dimensions/tolerances that require revisions. Required final deliverables At completion, I would like: complete native editable parametric CAD source complete assembly model STEP exports print-ready STL and/or 3MF files exploded assembly views hardware/fastener BOM recommended springs recommended servos/actuators recommended pins/bushings/bearings where applicable assembly guidance mechanism drawings where useful PCB mounting dimensions important fit/tolerance documentation I am not looking for STL-only delivery. Editable native CAD is important because the project will continue evolving as the electronics are developed. Ownership/confidentiality This is a personal-use project inspired by a fictional third-party product. I am not asking for or claiming ownership of any Yu-Gi-Oh!/Konami IP. I do want ownership/assignment of the original CAD, mechanical design, mechanisms, and other original work specifically created for this commission, to the extent allowed by the Upwork agreement. I would also prefer that project files and commissioned designs not be publicly redistributed or published without my permission. Experience I am looking for Relevant experience includes: Mechanical Engineering Mechanical Design Electromechanical Product Design Fusion 360 / SolidWorks / Onshape or similar parametric CAD FDM 3D-printable assemblies Design for Manufacturing functional prototyping servo-driven mechanisms spring/latch mechanisms sliding/retractable mechanisms folding assemblies electronics enclosures PCB integration moving cable/harness routing tolerance/fit design Experience producing functional mechanisms and physical prototypes is much more important to me than photorealistic rendering. Current prototype hardware Initial electronics already purchased/being tested include: ESP32 development board PN532 NFC reader 12 × 12 × 7 mm through-hole momentary tactile switches on/off rocker switches piezo buzzer module 3.7 V 2000 mAh LiPo battery, approximately 60 × 36 × 7 mm breadboard/prototyping hardware NFC tags planned IR/optical sensor prototypes The final custom PCB dimensions, screen, actuators, and exact sensor components are not yet finalized. I am therefore looking for someone comfortable developing the mechanical architecture while allowing some internal electronics geometry to remain flexible until prototype testing provides final measurements. I am happy to discuss scope and adjust individual mechanisms based on engineering practicality. I am more interested in developing something robust and genuinely functional than forcing a particular mechanism that turns out to be unreliable. Pricing is not set in stone - I am willing to negotiate to make sure the asking rate is fair.