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finishing up talk 

Signed-off-by: Sean Cross <sean@xobs.io>
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Sean Cross 2019-01-11 10:25:41 +08:00
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@ -557,7 +557,9 @@
<h3>Here's what we sent to the factory</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 received the file, along with a sample PCB, and we got to talking. They understood roughly what the usecase was, and they had some suggestions. They made some modifications to the STEP file and sent it back to me for approval.
Here's what we sent to the factory. FreeCAD generated this STEP file, and we just emailed it to them. They
received the file, along with a sample PCB, and we got to talking. They understood roughly what the usecase was,
and they had some suggestions. They made some modifications to the STEP file and sent it back to me for approval.
</aside>
</section>
<section>
@ -566,9 +568,56 @@
<source data-src="img/final-model-spinning.mp4" type="video/mp4" />
</video>
<aside class="notes">
I'm really happy with this. You can see the changes they made. They added the lifters on the bottom, which is what causes those holes. You wouldn't normally notice them, but they give those latches that let the PCB snap into place. They also added the grips on the side, which are just kind of a nice touch. Overall they managed to quickly understand the design and make some simple improvements. And then I was able to approve their design decisions, including the extra cost incurred from the additional lifters, and get the tool made.
I'm really happy with this. You can see the changes they made. They added the lifters on the bottom, which is
what causes those holes. You wouldn't normally notice them, but they give those latches that let the PCB snap
into place. They also added the grips on the side, which are just kind of a nice touch. Overall they managed to
quickly understand the design and make some simple improvements. And then I was able to approve their design
decisions, including the extra cost incurred from the additional lifters, and get the tool made.
From this point, they took a few weeks to do the first draft of the mold, called T0. This is like a beta release: everything should be there, but it needs tuning. There will be flow defects, and it will be unpolished. The tool is still relatively soft at this point, and edits can be made easily. 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.
From this point, they took a few weeks to do the first draft of the mold, called T0. This is like a beta release:
everything should be there, but it needs tuning. There will be flow defects, and it will be unpolished. The tool
is still relatively soft at this point, and edits can be made easily. 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.
</aside>
</section>
<section>
<h3>3D Printed Prototype</h3>
<aside class="notes">
The factory wanted to create a 3D printed prototype. These were very accurate, but were heavier than the final
thing. They did this to ensure the PCB would fit. These 3D printers must be super fancy, because they're able to
handle the undercuts and weird features of the case.
</aside>
</section>
<section>
<h3>Cutting Steel</h3>
<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.
</aside>
</section>
<section>
<h3>T0 Shot</h3>
<aside class="notes">
After they finish milling, they do a test shot. Usually this is in black, 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.
</aside>
</section>
<section>
<h3>Finishing</h3>
<aside class="notes">
They may need to move on to subsequent test shots as they refine the tool. Each step takes a few weeks, so the
fewer test shots you need the better. Factories are getting pretty good now in that most of the ones I've worked
with get it right on the first or second try. After they're happy with the tool, they harden it, which means it's
good for about 100,000 shots before it needs to be refinished.
</aside>
</section>
<section>
<h3>Manufactured!</h3>
<aside class="notes">
And then you have your final tool, ready to shoot thousands of copies of your model!
</aside>
</section>
</section>
@ -701,10 +750,12 @@
{ src: 'plugin/zoom-js/zoom.js', async: true },
{ src: 'plugin/notes/notes.js', async: true },
{ src: '//cdn.socket.io/socket.io-1.3.5.js', async: true },
{ src: 'plugin/multiplex/master.js', async: true },
// and if you want speaker notes
{ src: 'plugin/notes-server/client.js', async: true }
/*
{ src: '//cdn.socket.io/socket.io-1.3.5.js', async: true },
{ src: 'plugin/multiplex/master.js', async: true },
// and if you want speaker notes
{ src: 'plugin/notes-server/client.js', async: true }
*/
]
});
</script>