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Building A Micrometer-Level Displacement Sensor With 3D Printed Parts
A DIY displacement sensor built with 3D printed parts and an opto-interrupter achieves sub-two-micron repeatability. The design uses a central stylus with a knife-edge blade that modulates light reaching a photodiode, with circular flexures preventing unwanted movement. Compared to a previous version, this iteration reduces non-linearity, improves repeatability to better than 2 microns, and is significantly easier to mount, making it a practical precision measurement tool despite using relatively crude printed components.