design for manufacture

9 Articles

Design And Testing Of The Form 2

October 8, 2016 by 1 Comment

Formlabs makes a pretty dang good SLA printer by all accounts. Though a bit premium in the pricing when compared to the more humble impact of FDM printers on the wallet, there’s a bit more to an SLA printer. The reasoning becomes a bit more obvious when reading through this two part series on the design and testing of the Form 2.

It was interesting to see what tests they thought were necessary to ensure the reliable operation of the machine. For example the beam profile of every single laser that goes into a printer is tested to have the correctly shaped spot. We also thought the Talcum powder test was pretty crazy. They left a printer inside a sandblast cabinet and blasted it with Talcum powder to see if dust ingress could cause the printer to fail; it didn’t.

The prototyping section was a good read. Formlabs was praised early on for the professional appearance of their printers. It was interesting to see how they went from a sort of hacky looking monstrosity to the final look. They started by giving each engineer a Form 1 and telling them to modify it in whatever way they thought would produce a better layer separation mechanism. Once they settled on one they liked they figured out how much space they’d need to hold all the new mechanics and electronics. After that it was up to the industrial designer to come up with a look that worked.

They’re promising a third part of the series covering how the feedback from beta testing was directed back into the engineering process. All in all the Form 2 ended up being quite a good printer and the reviews have been positive. The resin from Formlab is a little expensive, but unlike others they still allow users to put the printer in open mode and use other resin if they’d like. It was cool to see their engineering process.

Tiling Your TV Remote

May 8, 2016 by 35 Comments

The Tile is a small Bluetooth chip, speaker, and enough battery for a year in a keychain format. If you lose your keys in the morning, simply use the app on your phone to find the keychain. If you lose your phone simply get out your second phone.

This planned obsolescence didn’t jive with [JM] when his Tile stopped being discoverable. He didn’t want to toss a gadget that had served him so well into the landfill. So, like any good hacker, he cracked its plastic case open.

The Tile itself is a really interesting product. The largest component is the battery which has tabs spot-welded to its surface. Attached to those is a well laid out board. [JM] points out the clever use of spring contacts to engage the piezo element for the speaker as a nice example of good design for manufacture.

The hack itself was pretty easy to complete. Some electrical tape and soldering was all it took to embed the tile into the remote. Now he can take out his phone and press a button to hear a forlorn beep coming from under the couch cushions.