This is amazing. Thanks to industrial designer Christian Poulsen, you can make yourself a mini BB-8 droid.
He has a fully detailed 6 step break down on how you can make your own , which can be seen below or at source here.
Step #1: Splitting Sphero 1.0
The first step was to split open the Sphero along the part line using a hack saw, being careful not to saw through the internal chassis.
Step #2: Embedding the magnet
- Once I split it apart, I needed to attach the internal magnet.
- The internal chassis of the Sphero has a post that pushes against the top of the sphere and acts as somewhat of a shock absorber. It’s to this post that I attached the 1 3/4″ neodymium magnet ring.
- I then cleaned up the edges of the sphere with a utility knife and used hot glue to reattach the two halves with the newly magnetized structure inside.
Step #3: Design and fabricate the head
- I then began work on the head. I built it in Rhino over a screenshot from the trailer to make sure I had the proportions right.
- I milled out my design on a CNC using polyurethane foam.
- I then used wood spackle to finish the surface of the foam.
Step #4: Masking and Painting
- To get the paint job right, I laser cut the designs out of tape to mask off the different colors. I used gray plastidip for the base coat. I chose plastidip because it is more opaque than regular spray paint and wanted to block out the flashing LEDs (a glowing green droid just wouldn’t work for me).
- After the base coat was dry, I coated it with orange spray paint.
Step #5: Finishing coats
After masking out the orange I hit it with a coat of white, added the sharpie details and finally finished it with a clear coat enamel. The top coat was particularly important to get just right, to reduce as much friction as possible between the head and body.
Step #6: Add magnets and felt
- After the paint was completely dry, I embedded a 1 3/8″ neodymium magnet disc in the head and I added a small adhesive felt pad so that it can slide easily across the surface of the body.
- I used a drill press to sink the magnet in just deep enough to be flush with the surface and glued it in place before attaching the felt pad over it.
- The droid is controlled by bluetooth through the Sphero app, but also has a mind of its own. Because it’s now more top-heavy and tends to lean, the gyroscope will try to correct the lean, and it will keep on rolling in whatever direction it’s pushed.