My high-level goals at the outset were to create an electronic card that is highly interactive, can be programmed, and shows off my nerdy side. Store-bought cards usually just play a single audio clip when you open them, but I wanted to add a wider range of sounds and more ways to trigger them. Different types of effects other than audio would be cool as well; I've never seen a card with lights, for instance. Making the card re-programmable would serve two main purposes: enabling software fixes and upgrades after construction, and introducing people to the idea of modifying and extending their gift. Few of my family members know any code, but I like to press the topic in hopes they'll come to learn and enjoy it in time. In addition to being able to program it, adding operating notes and source code listings directly to the card would help encourage them to learn more. It's also a expression of my character that's visible on the card's exterior.
The design is an electronic keyboard with four keys that can only play one note at a time. Each key represents one bit in an LSB-first four-bit number that selects a note out of a single-octave scale ranging from A3 to A4 in half-step increments. For example, pressing just K0 (the leftmost key) plays A3. Pressing K0 and K1 together plays B3 flat. This scheme leaves a few key combinations left over, so I plan to use those as triggers for additional sequences or modes in the future.
The materials are a mix of corrugated cardboard, cardstock, and glue. The cardboard makes for a much chunkier card than I had intended, but it actually feels nice and solid in the hands. The keys are implemented by partially cutting tabs into one side of the cardboard so they would fold down while remaining attached to the rest of the body. Underneath are rubber dome buttons that give the keys lots of travel and don't produce unwanted clicking noises. Paired with each key is a colored LED that lights when the key is pressed. The LEDs are Adafruit Sequins that have large solder pads and built-in current-limiting resistors. These make assembly much easier. Both the LEDs and keys are wired with slices of old IDE hard drive cables that thread through the cardboard up to the controller at the top half of the card. The controller is an ATMEGA328P in a 28-pin DIP package. At first, I thought that package would be too physically large, but it actually just fits within a cutout in the cardboard. Plus, I've only ever soldered through-hole parts before, so it improved ease of assembly. In addition to the buttons and LEDs, the controller is connected to the speaker driver, programming port and battery. The driver is another Adafruit product based on the PAM8302 that has adjustable volume and a shutdown pin. It drives an 8 ohm 0.25 watt speaker with a diameter of 1.5" that fits nicely next to the controller at the top of the card. The programming port at the top is connected directly to the VCC, RESET, MISO, MOSI, SCK, and GND pins on the controller. The programming protocol is specified in application note AVR910, and it works perfectly with the USBTinyISP programmer I have in my toolbox. Adjacent to the port is the battery holder and a switch to direct power from either the port or the battery. The battery holder opens at the edge of the card and accepts CR2032 coin cell batteries.
I was careful to plan ahead and worked for several weeks before the big holiday party where I would give out the cards, but I still completely blew the deadline and didn't get the first set of five cards out until after New Years. Despite that disappointment, this was one of the most fun and satisfying projects that I had ever worked on. On their own, the electronics, software, and mechanics are very simple, but bringing them all together was both challenging and rewarding. When people did finally receive their cards, they genuinely enjoyed them. All of the cards worked well even after some use, though failures did include paper partially detaching from the cardboard and thin speaker wires breaking off of the driver.
With this year's holidays coming up, I definitely want to change things to make the cards easier to manufacture. The point to point wiring in the current version consumes requires several hours of soldering, cutting, and stripping for a single card. Therefore, I want to finally learn PCB design so that I can simply wire pairs of boards together and sandwich them between paper and/or cardboard. In addition, I want to add many more features to the software (available here) like pre-programmed music sequences and a Simon-like game. Some fancy pop-outs that add additional dimensions when the card is opened would be cool too.