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Sean Cross 2019-01-16 11:24:37 +08:00
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@ -158,6 +158,23 @@
also see the linear sliders.
</aside>
</section>
<section>
<h3>Into the Machine</h3>
<img id="bunnie-ij-machines" alt="Rows of injection molding machines" data-src="img/bunnie-ij-machines.jpg">
<cite for="bunnie-ij-machines"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
Here's another shot with a lot more machines. This was taken at a different factory at lunchtime, when the
factory floor clears out.
</aside>
</section>
<section>
<h3>Into the Machine</h3>
<img id="bunnie-ij-machines-2" alt="Rows of injection molding machines" data-src="img/bunnie-ij-machines-2.jpg">
<cite for="bunnie-ij-machines-2"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
More machines. Believe it or not this was a different factory.
</aside>
</section>
<section>
<h3>Pulling a Shot</h3>
<video data-autoplay>
@ -219,6 +236,15 @@
somehow. Ejector pins slide through the tool and pop the piece out, leaving it clean for another shot.
</aside>
</section>
<section>
<h3>Ejectors</h3>
<img id="bunnie-ejectors" data-src="img/bunnie-ejector-pins.jpg" alt="Ejectors from another mold, clearly visible">
<cite for="bunnie-ejectors"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
And just so you get a good idea of what ejectors look like, here's a mold base that's been partially diassembled.
You can see just how many ejector pins there are on this relatively large piece.
</aside>
</section>
<section>
<h3>Cases on Runners</h3>
<img data-src="img/factory-cases-on-runner.jpg">
@ -334,7 +360,7 @@
</aside>
</section>
<section>
<h3>FreeCAD can read KiCad files</h3>
<h3>FreeCAD can read KiCad PCBs</h3>
<img data-src="img/freecad-kicad.png" alt="KiCad PCB inside FreeCAD">
<aside class="notes">
This is huge for ensuring your PCB fits. FreeCAD will read any STEP models for components that exist. It will
@ -579,7 +605,7 @@
</aside>
</section>
<section>
<h3>Here's what we sent to the factory</h3>
<h3>Here's what we submitted</h3>
<img data-src="img/freecad-sent-to-factory.png" alt="STEP model we sent to factory">
<aside class="notes">
Here's what we sent to the factory. FreeCAD generated this STEP file, and we just emailed it to them. They
@ -588,7 +614,7 @@
</aside>
</section>
<section>
<h3>And here's what they sent back</h3>
<h3>And here's what they made</h3>
<video data-autoplay>
<source data-src="img/final-model-spinning.mp4" type="video/mp4" />
</video>
@ -609,22 +635,39 @@
</aside>
</section>
<section>
<h3>Cutting Steel</h3>
<h3>Cutting Steel - EDM</h3>
<img id="bunnie-edm" src="img/bunnie-edm.jpg" alt="An EDM machine cutting steel">
<cite for="bunnie-edm"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
Once we approved the 3D printed prototype, they started cutting steel. They use a variety of techniques here, but
it usually starts with wire EDM. This process takes a few weeks.
Once we approved the 3D printed prototype, they started cutting steel. They use a variety of techniques here, and
frequently use EDM. This process involves cutting a soft copper positive with a CNC tool, then passing high
current through the copper as it comes near steel. They run dielectric fluid on it both to cool the piece and to
help the electrons ablate the steel.
</aside>
</section>
<section>
<h3>T0 Shot</h3>
<img data-src="img/tomu-case-defect.jpg">
<img id="bunnie-pvt-case-outside" data-src="img/bunnie-pvt-case-outside.jpg" alt="Outside of the Novena case">
<cite for="bunnie-pvt-case-outside"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
After they finish milling, they do a test shot. Usually this is in black, because it helps them to tune features
After they finish milling, they do a test shot. Usually this is not in the final color you specified, because it
helps them to tune features
such as how quickly to flow plastic. This T0 shot also lets them test to make sure it fits the final product. The
tool is still relatively soft, so changes can easily be made. If they need to remove material, they simply grind
it off. If they need to add material, they weld it on and then grind it off.
A good plastics vendor will have a functional tool after T0, but it's not at all uncommon to have to do T1, T2,
and more. This test shot will usually be in black, because it shows lots of defects very easily.
and more.
</aside>
</section>
<section>
<h3>T0 Shot - Annotated</h3>
<img id="bunnie-pvt-case-t0-explained" data-src="img/bunnie-pvt-case-t0-explained.jpg" alt="Outside of the Novena case">
<cite for="bunnie-pvt-case-t0-explained"><small>&copy; bunnie@bunniestudios.com</small></cite>
<aside class="notes">
This is an annotated version of the case. You can see three major problems here: flow lines,
where the plastic partially cooled as it was still moving. Knit lines are where two rivers of molten plastic
meet. And sink marks, where not enough plastic flowed, and features on the inside can be seen through on the
other side. The factory will tune the mold and the flow rate to address these issues.
</aside>
</section>
<section>
@ -638,6 +681,7 @@
</section>
<section>
<h3>Manufactured!</h3>
<img src="img/manufactured.jpg" alt="Bag of Tomu cases">
<aside class="notes">
And then you have your final tool, ready to shoot thousands of copies of your model!
</aside>