Calculating the Extrusion Length of the Pyramid

 Our excitement at producing our first dozen pyramids was short lived, as we realized that the extrusion in the pyramid was far too short to press the button in any position, and if the button could be pressed, the pyramid would run into the LEDs on the board. 

Pyramid hitting the LEDs

We spent the next week calculating the necessary extrusion length to press the button without running into any of the PCB components. Based on the new length, we also decided to order shorter LEDs, so the battery holders would be the tallest parts on the PCB. We also had to determine the heights of the ledges on the sides of the pyramid, which keep it from falling out the front of the yo-yo, so that when the button is in the unpressed position, the pyramid still fits underneath the cover and rim.

 

Some calculations for optimizing extrusion length and ledge height

    

Updated pyramid design