Deployable by Design With Bunnie Huang, Nadya Peek, and Joi Ito

We follow [bunnie]’s blog as he posts interesting and usable information quite regularly. [bunnie] posted about a video of a recent talk he did at MIT Media Lab with Nadya Peek and Joi Ito. This was in lieu of his monthly “name that ware” competition, which is worth looking into as well.

The talk is focused on small volume manufacturing and the experiences that the speakers have under their collective belt is large enough that the conversation takes a turn from how to do things in practice, to the theory and technique of manufacturing on a philosophical level.

[bunnie] prefaces the conversation with an explanation of some of the design and manufacturing processes involved when working on the circuit stickers project. He talks about the importance of testing the product and the complex test jig that is required to quality check a simple (in comparison to the test jig) product. [bunnie] shares an overview of the project timeline and where some extended design stages might be found in unexpected places.

The design and manufacturing process is discussed on many levels throughout the talk. Among the points that are insightful, we certainly found ourselves a little jelly of all the time [bunnie] gets to spend in Shenzhen.

If you’re not familiar with [bunnie]’s blog you can check it out at Pro Tip: you can spend the better part of your workday browsing topics in the sidebar on the right.

We have covered the MIT Media Lab before, including a trip to Shenzhen that is discussed in the Media Lab talk by [Joi] and [bunnie]. Another interesting interview at SXSW earlier this year by [Sophi Kravitz] who spoke with [Sunanda Sharma] about mediated matter.

Buying cheaper electronics and not saving money

As an engineer at Spectrum Design in Minneapolis, [Carl] works with clients to get their product out to the masses. When designing a new USB-powered device, one client thought it would be a great idea to include a USB car charger with the device. The client promptly ordered a few thousand car chargers from China and everything was going swimmingly.

Everything was fine, of course, until [Carl] decided to test the Chinese car chargers with the client’s device. The USB PHY burnt out in short order, and the likely culprit was a shorted 12 volt regulator. This demanded a closer inspection, so after cracking open the charger [Carl] was amazed at what he found.

Yes, what you see on that circuit board is accurate. The manufacturer of these car chargers never even populated the switched mode regulator for this car USB charger.  Amazing, considering a single 10 cent 7805 DC regulator would have almost worked for this application.

If there was ever an example of being careful when purchasing the cheapest possible product to increase profit margins, this would be it.

Ever the engineer, [Carl] sent this into the tip line as a Word document. That’s available here, along with a slide show of the pictures [Carl] snapped.

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