DIY Split-Flap Display

This is a work in progress split-flap display. Each module can flip between 40 unique characters: letters, numbers, and a few symbols. Multiple modules fit perfectly alongside each other to build bigger displays. The primary design goal was to make something that's possible to fabricate at home in small or single quantities and can be customized and built by an intermediate hobbyist at a reasonable price. This meant using widely available materials and avoiding any tooling with a high upfront cost. Following that philosophy, the design uses store-bought vinyl stickers for the letters, is driven by an ubiquitous and cheap 28BYJ-48 stepper motor, and uses common PVC ID badge cards cut to shape for the flaps (though custom die-cut flaps are also available). Even the enclosure, spool, and gears, which are all made from laser-cut MDF, can be easily ordered online.