[Introduction]

7/03/2024 - Minor tweak to the print profiles. I adjusted the walls and such for the main gear, making it solid through the shaft portion. A few people commented about how it broke on them, and so seemed prudent to get more plastic in there. 

I also cleaned up the updates here so there's less walls of text. 

6/27/2024 - I just wanted to say thank you to everyone that has downloaded and printed the shuffler! I've had a few bumps in the road, and a few bugs to work out. I appreciate you all, the comments, the suggestions, and I'm sorry for any of the issues caused by trying to get these early bug fixes and everything out there.

I haven't been to keen on the card shufflers available commercially, and feel most of the ones designed for 3d printing don't really elevate themselves to a consumer level product. Thus, this card shuffler was born. I wanted something stylistic, and not just functional. Inspired by old printing presses, with those cast iron frames. Although, it looks a bit like a boiler too, I'd say.

Sized for standard playing cards. (64x89mm + plus sleeves, or there abouts, is the max size card it'll shuffle). I sized it to be able to shuffle a full skip-bo deck, which is 160 cards. It can do about 80 sleeved cards, in testing. Might have to make an extra tall version for bigger decks and big sleeved decks! 

It's been running smoothly for me, especially since upgrading to O-rings. The grip on them is much better than the original TPU rollers. There are occasional jams that happen, when the cards don't fall right. I think as long as you aren't going too slow and keep a good pace, usually it's fine. Sometimes it helps to shift the whole thing back and fort slightly to shake the cards loose and get them to settle. 

[Hardware Required]

Featured Filaments

Bambu PLA Metallic Iron Gray

Bambu PLA Metallic Copper Brown

Bambu PETG-CF Brick Red

Bambu PLA Galaxy Nebula

Bambu PLA Glow Green

Bambu PLA Metallic Copper Brown

Bambu Matte Grass Green

Bambu Marine Blue

Bambu Lemon Yellow

Notes about Printing

I highly recommend using a smooth PEI bed. (It's not required, and you can absolutely print the whole thing on your bed of choice. I just highly recommend the Smooth PEI bed for PLA because it holds well, and for smaller parts with a thin profile on the bed, it tends to hold much better. Like the spacers I use in step 4.)

Hardware Required :

36x M2.6x8mm Self Tapping Screws (Bambu's BT2.6x8mm self tapping screws) (From the Bambu US Store)

9x MR128ZZ Ball Bearings (inner = 8mm, outer 12mm, height = 3.5mm, such as this one from Amazon, or from the Bambu US store)

4 O-Rings OD 24x2.5mm  ( From the Bambu US Store)

[Upgrading from the TPU Roller version]

If you've already printed the original tpu version of the card shuffler, but want to upgrade, please refer to the above graphic for the parts you'll need to reprint. Make sure you print 2 of the axels, pad drums, and the card holder/bracket. In addition you'll need two extra screws to secure the drums to the axels, and the 4 O-rings. 

If all you want to do is upgrade the pad drums, then you should be able to slide them on the original axles, however be aware that they aren't secured with friction like the TPU pads were, so you might need to glue them or use some other method to fix them once installed, if the fit is too loose. The new axels are slightly longer, but also have a hole for a self tapping screw to tap into. 

[Assembly]

Step1: Screw the end plates on. 

Step2: Assemble the two side card holders, then slot them in and screw them into the main body. 

Step3: 

• Install the o-rings onto the two drums.
• Install the bearing on the end of the shaft and then screw the end cap into place to keep it secure. 
• Insert the drum into place, and then insert the shaft through the drum and the main body. Install the set screw to set the drum into place.

(Caution: Do not overtighten! Loosen screw a little of bearings bind)

Step4: 

• Insert the bearings onto the shafts, followed by the spacer and then the gear. Make sure the bearing is fully seated.
• Make sure the gears are orientated right. The Arrow pattern on the gear should point in the direction of travel. Inward! 
• Screw the gears into place. 

(Caution: Do not overtighten! Loosen screw a little if gears bind)

Step5:

• The Tricky part
• For each gear there is a gear peg and the bearing. Insert the bearing into the end plate, and insert the gear peg into the gear. Make sure the gears are fully seated.
• I insert the small gear and then the large one. With the large one I try and angle it in a little, and use a little force to jam it into place. 
• You'll want to try and rotate the pads so the flat ends are opposite each other before installing the large gear. 

Step6: Insert the bearings into the gear bracket and make sure they are fully seated. Screw the bracket into place. 

Step7: 

• Insert the bearing into the crank arm, and then sandwich it between the peg and knob, and secure it with a screw. 
• Screw the crank arm onto the large gear's shaft with an end cap to help keep it secured. 
• Shuffle some cards! 

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