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Saturn Cartridges - Custom Shells

Saturn Cartridges - Custom Shells

This page gathers a collection of 3D printed custom Saturn cartridge shells, mostly used for Gamer's Cartridge.
All theses shells are not my personal work : theses were designed and 3D printed by Zone66x, and source for some of them can be found in his thingiverse page. Warm thanks to his dedicated work #top#

And no, theses cartridges are not for sale : theses are for my personal collection or giving to friends. Cartridges with regular Action Replay shell are however sometimes available for purchase on their own page.

Custom Shell #01 #anchor#

Custom Shell #01
Custom Shell #01
First custom shell 3D printed.
No logo, no indentation for label, but transparent plastic used.

Custom Shell #02 #anchor#

Custom Shell #02
Custom Shell #02
Pseudo Saturn Kai text added on front side.
Text and logo are a bit hard to notice.
2018/11/30: Reserved for Gamer's Cartridge PCB. Long time I didn't set up custom shell #smile#
2018/12/01: Mounted a PCB in this shell, but didn't yet had time to flash
Pseudo Saturn Kai, nor to verify that the cartridge works correctly #zzz#
The revision of the PCB used is Rev 3.3 (d), and the particularity of this cartridge is that
it uses same kind of voltage regulator as the one used in Wasca and was half-assembled
by Seeed Studio. This was my first try of PCB assembly service #smile#
CPLD and SD card socket were hand-soldered by myself because theses parts are
no longer available for sale. Additionally, the decoupling capacitors were
hand-soldered, because soldering theses after the CPLD makes the assembly
process a bit easier.
2018/12/11: Pseudo Saturn Kai is flashed and the cartridge works correctly #top#
In the picture below, the 4.7μF capacitor on the SD card socket is missing, but
I realized about the mistake and fixed it the next day #smile# I supose that the change
in order and quantity of ICs to solder caused this mistake, and I will check for
this capacitor when soldering decoupling ones so that this mistake shouldn't
happen in the future.
Custom Shell #02

Custom Shell #03 #anchor#

Custom Shell #03
Custom Shell #03
Another text test that came out very well.
Added cow logo on rear side.
2017/07/03: installed SGC PCB (rev 3.3 (b), blue color). Transparent enough to distinguish PCB shape and see LED lighting #smile#
2017/07/12: used in video in order to test cheat codes support in Pseudo Saturn Kai beta v6.117 #smile#

Custom Shell #03 (b) #anchor#

Custom Shell #03b
Custom Shell #03b
Text test with glow in the dark ABS.

Custom Shell #04 #anchor#

Custom Shell #04
Custom Shell #04
Text test inside shell.
So so results.

Custom Shell #05 #anchor#

Custom Shell #05
Custom Shell #05
White shell, texture very nice.

Custom Shell #06 #anchor#

Custom Shell #06
Custom Shell #06
Another white shell.
ABS plastic is semi-transparent, so no holes needed for LEDs !
2018/11/30: Reserved for Gamer's Cartridge PCB. Long time I didn't set up custom shell #smile#
2018/12/01: Mounted a PCB in this shell, but didn't yet had time to flash
Pseudo Saturn Kai, nor to verify that the cartridge works correctly #zzz#
The revision of the PCB used is Rev 3.3 (c), and the particularity of the PCB used is that
it had some defects around voltage regulator.
Theses are minor defects that shouldn't prevent cartridge from working, but it's better to put
this unique PCB in unique custom shell rather than putting it for sale in a regular shell #smile#
2018/12/11: Pseudo Saturn Kai is flashed and the cartridge works correctly #top#
Green LED looks a little faint over the white plastic, but is visible anyway.
Custom Shell #06 with PCB

Custom Shell #07 #anchor#

Custom Shell #07
Custom Shell #07
Metalic silver with label indentation.
The plastic is surprisingly semi-transparent : if shined from behind, light can be seen from the cow.
2018/12/01: I wanted to update this page about this cartridge, but I
don't have any remember when I prepared this cartridge #biggrin#
That's probably the last remaining black PCB I own. As shown in the pictures below,
result is visually so-so because of many stains remaining from hand-soldering.
Also, this was an occasion to test sticking of a label : as far I remember, this
required slightly adjusting label dimension (by 1mm or less) to get it fitting
into the enclosure.
PCB uses "EPM3032 ATC44-10N" CPLD which is versioned as "1.7" on sofware side.
This is not a common model of CPLD used in Gamer's Cartridge since I prefer to
use the "ATI44" flavor since it is resitant to higher temperatures and
had nearly equivalent price.
Unfortunately, the availability of CPLDs wasn't so good so that I had to use
"ATC44" chips from time to time. Well, this difference concern temperatures
over 70 degrees so whatever it may be, this shouldn't cause any problem #smile#
2019/10/03: Flashed with latest Pseudo Saturn Kai and sent to a friend.
Just before sending the cartridge, took a video featuring it #smile#
Custom Shell #07 with PCB
Custom Shell #07 with PCB
Custom Shell #07 with PCB

Custom Shell #08 #anchor#

Custom Shell #08
Custom Shell #08
Another metallic grey shell.

Custom Shell #09 #anchor#

Custom Shell #09
Custom Shell #09
Black shell. Didn't clean print surface properly making cover surface ugly.
2018/11/30: Reserved for Gamer's Cartridge PCB. Long time I didn't set up custom shell #smile#
2018/12/01: Mounted a PCB in this shell, but didn't yet had time to flash
Pseudo Saturn Kai, nor to verify that the cartridge works correctly #zzz#
The revision of the PCB used is Rev 3.3 (c), and the particularity of this cartridge is that
it uses same kind of voltage regulator as the one used in Wasca.
Mounting this PCB was an occasion to drill holes for LEDs : I was fearing that
plastic would break or crack, but that went way better than expected #top#
On the other hand, adjusting the position of the LEDs to their respective
holes was a bit laborious because of the PCB mounting mechanism used.
2018/12/11: Pseudo Saturn Kai is flashed and the cartridge works correctly #top#
It would had been smarter to drill the LED holes, and then solder the LEDs whith
front cover being installed (as done with #17), but positioning is OK anyway.
Custom Shell #09
Custom Shell #09

Custom Shell #10 #anchor#

Custom Shell #10
Custom Shell #10
Better black shell with white cow.
Actually maybe it's glow in the dark. Test it out #smile#

Custom Shell #11 #anchor#

Custom Shell #11
Custom Shell #11
Blue shell with glow in the dark cow.
2019/11/15: Reserved for Gamer's Cartridge PCB #smile#
2019/11/28: Pseudo Saturn Kai installed so that cartridge
is ready for use #smile#
LEDs are visible through their holes as expected. I still need to put a label on this shell
but except that no other kind of setup is remaining.
And, PCB uses good old "EPM3064" CPLD whose version can be seen as "1.3" from
Pseudo Saturn Kai version informations screen. This variation of CPLD was
used in early cartridge iterations such as Rev 3.1 and Rev 3.3.
Main characteristic of this CPLD is that LEDs are turned off on Saturn power on
while later versions (1.5 and 1.7) are keeping theses on until Pseudo Saturn Kai boot.

Custom Shell #12 #anchor#

Custom Shell #12
Custom Shell #12
Glow in the dark.
Acetone discoloration were used to weld label plastic to shell.

Custom Shell #13 #anchor#

Custom Shell #13
Custom Shell #13
Glow in the dark shell.

Custom Shell #14 #anchor#

Custom Shell #14
Custom Shell #14
Glow in the dark.
2019/11/15: Reserved for Gamer's Cartridge PCB #smile#
LEDs are visible through plastic so that shell won't have be drilled to see the LEDs.
2019/11/28: Pseudo Saturn Kai installed so that cartridge
is ready for use #smile#
LEDs are clearly visible even in bright environment so that it was a good choice to
keep shell as-is rather than drilling holes for LEDs on it. I still need
to put a label on this shell but except that no other kind of setup is remaining.
And, PCB uses good old "EPM3064" CPLD whose version can be seen as "1.3" from
Pseudo Saturn Kai version informations screen. This variation of CPLD was
used in early cartridge iterations such as Rev 3.1 and Rev 3.3.
Main characteristic of this CPLD is that LEDs are turned off on Saturn power on
while later versions (1.5 and 1.7) are keeping theses on until Pseudo Saturn Kai boot.

Custom Shell #15 #anchor#

Custom Shell #15
Custom Shell #15
Yellow shell.

Custom Shell #16 #anchor#

Custom Shell #16
Custom Shell #16
Green shell.

Custom Shell #17 #anchor#

Custom Shell #17
Custom Shell #17
Violet shell.
2017/07/14: installed SGC PCB rev 3.3 (b), red color, ENIG (gold) plating. When soldering LEDs, positioning was done with front cover installed so that they could fit perfectly with holes on cover.
Holes for LEDs is relatively small, but result is better than expected : LEDs can be seen normally within a 10-15 degrees angle, hence "not too much, not too few" in order to see LEDs #top#
PCB uses "EPM3032" CPLD which has twice less logic than CPLDs used so far. I had to make small change (LEDs are not turned off on reset, hence will light until end of Sega logo display) in order to get firmware fitting in the CPLD, but except that everything is as before.
This custom cartridge #17 is the second one using such EPM3032 CPLD : first one where CPLD was developed and tested was soldered for use on Action Replay shell (with spacers used on LEDs), and this second one was then flashed and tested in order to be completely sure that next cartridges using such CPLDs would work fine #smile#
Custom Shell #17 with PCB

Custom Shell #18 #anchor#

Custom Shell #18
Custom Shell #18
Tangerine shell.

Custom Shell #19 #anchor#

Custom Shell #19
Custom Shell #19
Red shell.
Got discolored during acetone welding.

Custom Shell #20 #anchor#

Custom Shell #20
Custom Shell #20
Purple shell.
Questionable ABS quality.
2017/09/22: Offered to Stac, with the red PCB pictured below #smile#
Custom Shell #20
Custom Shell #20

Custom Shell #21 #anchor#

Custom Shell #21
Custom Shell #21
Gold shell.
Plastic semi transparent if thin enough.
2017/09/22: PCB populated, but CPLD not programmed yet #zzz#
2017/10/xx: CPLD programmed with firmware 1.5 (EPM3032 ATI44-10N).
Then, installed Pseudo Saturn Kai without problems #top#
2018/11/30: Some parts helping to close the shell broke when trying to open the cartridge #tsss#
Also, the label enclosure seems quite fragile so that it should be safer not to stick a label on this cartridge.
Custom Shell #21 with PCB
Custom Shell #21 with PCB

Custom Shell #22 #anchor#

Custom Shell #22
Custom Shell #22
Red shell.
New clip system.

Custom Shell #23 #anchor#

Custom Shell #23
Custom Shell #23
Another red shell.
New clip system.

Custom Shell #24 #anchor#

Custom Shell #24
Custom Shell #24
Light blue shell with "Saturn Gamer's Cartridge" text printed.
2019/11/15: Reserved for Gamer's Cartridge PCB #smile#
In a dark enough environment, light can be seen through plastic
so that this shell won't have be drilled to see the LEDs.
2019/11/28: Pseudo Saturn Kai installed so that cartridge
is ready for use #smile#
LEDs are barely visible in bright environment but should be just enough in a dark one.
And, PCB uses regular "EPM3032 ATI44-10N" CPLD whose version can be seen
as "1.5" from Pseudo Saturn Kai version informations screen.
Main characteristic of this variation of CPLD is that both LEDs are turned on until
Pseudo Saturn Kai boots.

Custom Shell #25 #anchor#

Custom Shell #25
Custom Shell #25
Lime shell.
Plastic quality really good. Layer lines very uniform.
2019/11/15: Reserved for Gamer's Cartridge PCB #smile#
In a dark enough environment, light can be seen through plastic
so that this shell won't have be drilled to see the LEDs.
2019/11/28: Pseudo Saturn Kai installed so that cartridge
is ready for use #smile#
LEDs are clearly visible through plastic, but surface itself is slightly "sticky".
I don't know if it is inherent to the material itself, or if it can be removed
with appropriate cleaning. As it's not problematic enough, I plan to let that as-is.
And, PCB uses regular "EPM3032 ATI44-10N" CPLD whose version can be seen
as "1.5" from Pseudo Saturn Kai version informations screen.
Main characteristic of this variation of CPLD is that both LEDs are turned on until
Pseudo Saturn Kai boots.

Custom Shell #26 #anchor#

Custom Shell #26
Custom Shell #26
Transparent shell with text.
New printer settings to make plastic more transparent #top#
2017/07/03: installed SGC PCB (rev 3.3 (b), blue color). Super transparent that makes visible sunlight coming holes for JTAG header #hehe#
→ Can see PCB shape, and where main parts (CPLD, flash chips, SD card connector) are located, but can't read what's written on ICs.
2017/07/12: used in second half of video about cheat codes support in Pseudo Saturn Kai beta v6.117 #smile#

Custom Shell #30 #anchor#

Custom Shell #30
Custom Shell #30
Custom Shell #30
Custom Shell #30
Custom Shell #30
Custom Shell #30
Three shells with micro SD card and USB port enclosures.
Supports large PCB so that it is compatible with Rev 2f and Rev 3.2 PCB revisions.
2017/07/03: installed SGC+USB PCB (rev 3.2, green color) in one shell. Had to drill holes for SMD LEDs, with mixed success. Anyway, that's more than enough for my personal purposes #hehe#

Custom Shell #31 #anchor#

Custom Shell #31
Custom Shell #31
Red shell with SD card (standard size) and two USB port enclosures
For use with future (TBD) wasca prototype #smile#

Custom Shell #32 #anchor#

Custom Shell #32
Custom Shell #32
Another shell for wasca prototype, with yellow transparent plastic.
Broke one clip when trying to open it #tsss# Still my favorite shell anyway #love#
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