Enso-90: Brushed Semi-Auto Nerf Blaster

This is still a work in progress. Some adjustment with parts (especially springs) will be needed. 

The Enso-90 Brushed nerf blaster is semi-auto and uses a modified Protean geared pusher attached to a GnK-90 dart rotation system (specifically HackOnWheel's remix) with Chance's Freerunner grip and single stage 25mm Traceur cage design. I haven't tested if the other Freerunner cages will work.

Traceur micro-flywheels and Kraken motors on 3S hit around 110-120 fps. Performance for this blaster was made with HvZ / low cap in mind, not competitive performance.

Mags (which hold 20 darts and use Talon bodies and springs) are interchangeable with the Gnk, feeding on the left side of the blaster instead of the top. Lipo battery is stored in the grip, secured with a thumbscrew. The top cover of the blaster hinges open for easier access to the parts, and is held in place near the rear with a 35mm printed take-down pin. There's storage space for x2 spare 35mm pins in the top cover. The hole in the Stock Socket is a sling mount. I've had 3d printed rings break on me, so this is for looping a circle of paracord or webbing, then attaching the sling to that.

• Parts used:
  • The turntable uses x1 F683zz 3x7x3mm Flanged Ball bearing
  • 3M 5mm, 10mm, 12mm, 15mm, 20mm, 40mm, (x2 optional 50mm screws to reinforce front grip)
  • 3M hex nuts
  • 3M Heat inserts (4mm tall)
  • extension spring (for protean pusher)
  • compression springs (for GnK Mag Dart Locks, Mag Catch, Mag ejector, Trigger, and front grip slide)
  • x1 10A Rocker Switch (the pins have to be bent to the side to fit in Middle Lower Frame's wire channel)
  • x1 21A Microswitch
  • XT30s
  • 18g wire
     
• Printed in a variety of PETG with a Prusa Mk4S:
  • Layer Height
    • 0.16mm layer height for all the GnK inner mechanisms,
    • 0.2mm layer height for all of the Protean inner mechanisms,
    • 0.25mm layer height for everything else.
  • 4 walls.
  • supports and brims for small parts as needed
  • Infill
    • 50% infill with Gyroid pattern for the Traceur 25mm cage, Motor cover, and protean trigger/gear/pusher.
    • 25% infill with Adaptive cubic infill pattern everywhere else.

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UPDATES - 

9/29/24

• The current muzzle and suppressor design doesn't print well for me, the tolerances of the threads are way too tight and need to be adjusted. I don't recommend printing it at this time.
• Known issue with current trigger and rev switch mechanism limits how fast you can fire the blaster. Full actuation of the turntable mechanism and the pusher turns off the rev switch/motors near the end, resulting in additional time needed for the motors to speed up again in between shots. I might make a separate rev trigger design adjustment to the grip and protean frame mechanism area later to address this.

• Using a cut down version of MeinGonk's cool GnK 90-degree dart rotation mechanism (and HackOnWheels' modifications to the same system) updated for Brushed motor and Traceur flywheels. I also widened the hole for the Mag Follower A to fit piece of filament as the axis pin.
   
• Using the 25mm Traceur Cage and a cut-down Grip design from Chance's Freerunner + inspiration for the rev switch internals. 
   
• Using modified parts from Flygonial's Protean for the Mech Frame, Trigger, and Pusher, and Take-down pin designs.
   
• Front grip is a modified version of Qwermakes's MP7 grip to have 3 locked positions (0 degree, 45 degree, and 90 degree) and be slightly longer.