Near Chaos Robotics MicroSwitch Assembly

Here's the full process for assembling one of the tiny MicroSwitch's I've designed. Assembled with a few inches of wire on each side they weigh in at 6.7g. The main body is 1/4" thick (4 layers of 1/16" material) and 0.65 x 0.5875". I suggest a small flathead driver that fits snugly into the slot with an insulated handle for operation.

Here's the pile of parts you start with for two complete switches.

The contacts have been prepped with small solder bulges to improve contact.

Wires have been soldered to the output side. This is done prior to assembly to avoid melting the delrin housing.

The 2-56 screws are threaded through the bottom plate by at least 1/8" to allow the next two layers of delrin to slide into place. (the top and bottom layers have a smaller hole diameter and help keep the switch together prior to the addition of nuts or attachment to threaded holes in the robot.)

Layer two is added.

The output contacts are slid into place with the solder bumps facing up.

The 3rd layer of delrin is added.

The copper paddle switch is dropped in over the output contacts.

The last layer is added and the 2-56 screws are threaded completely through the body. At this point you add 4 2-56 nuts or screw the switch into pre-tapped holes in whatever mount solution you are using.

This is the on position. (slot is inline with outputs)

This is the off position. (slot is at roughly 45deg angle from outputs)