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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>© 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>© 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>© 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>© 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>© 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>© 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> | ||||
|   | ||||