production

28 Articles

Using Lasagna To Make Cost-Saving Molds

January 25, 2018 by 7 Comments

Building a one-off prototype is usually pretty straightforward. Find some perfboard and start soldering, weld up some scrap metal, or break out the 3D printer. But if you’re going to do a production run of a product then things need to have a little more polish. In [Eric Strebel]’s case this means saving on weight and material by converting a solid molded part into something that is hollow, with the help of some lasagna.

What [Eric] walks us through in this video is how to build a weep mold. First, the solid part is cast in silicone. Using the cast, some “sheet clay” is applied to the inside which will eventually form the void for the new part’s walls. The clay needs to be flush with the top of the mold, though, and a trick to accomplish this task is to freeze the mold (next to the lasagna) which allows the clay to be scraped without deforming.

From there, the second half of the mold is poured in, using special channels that allow the resin to “weep” out of the mold (hence the name). This two-part process creates a much more efficient part with thin walls, rather than the expensive solid prototype part.

[Eric] is no stranger around these parts, either. He’s an industrial designer with many tips and tricks of the profession, including a method for building a machining tool out of a drill press and a vise as well as some tips for how to get the most out of a low-volume production run of a product you might be producing.

Continue reading “Using Lasagna To Make Cost-Saving Molds” →

Taking A Guitar Pedal From Concept Into Production

December 20, 2017 by 22 Comments

Starting a new project is fun, and often involves great times spent playing with breadboards and protoboards, and doing whatever it takes to get things working. It can often seem like a huge time investment just getting a project to that functional point. But what if you want to take it to the next level, and take your project from a prototype to a production-ready form? This is the story of how I achieved just that with the Grav-A distortion pedal.

Why build a pedal, anyway?

The author, shown here with bandmates.

A long time ago, I found myself faced with a choice. With graduation looming on the horizon, I needed to decide what I was going to do with my life once my engineering degree was squared away. At the time, the idea of walking straight into a 9-5 wasn’t particularly attractive, and I felt like getting back into a band and playing shows again. However, I worried about the impact an extended break would have on my potential career. It was then that I came up with a solution. I would start my own electronics company, making products for musicians. Continue reading “Taking A Guitar Pedal From Concept Into Production” →

Less Than Production, More Than One-Offs

November 14, 2017 by 18 Comments

We build things we think are cool. Sometimes, other people agree with us and they want a copy of what we’ve built. If you’re lucky enough to have an enviable product but you’re not ready for full-scale manufacturing, you may be looking at a low-volume production run. [Eric Strebel] walks us through one such instance where he makes some custom color swatches for a show. Video after the break.

[Eric Strebel] is an industrial designer so he plays to his strengths by designing the swatch shape, jig, tool, and hangers. He hires out the painting, laser cutting, and CNC machining. This may seem like a simple statement but some of us have a hard time paying other people for things we’re capable of learning. In some cases, we just have to pay the professionals to do it correctly and keep our focus.

The mentality of small runs in this video is perfect for people who sell on Tindie or want to make more than a handful of consistently nice parts. Our own [Lewin Day] recently talked about his experience with a run of 200 mixers called gMix.

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Automate Wire Prep With A Robot Wire Cutter

October 28, 2017 by 21 Comments

When you move from one-off builds to production scale, perhaps to meet that Kickstarter commitment or to keep your Tindie store stocked, you’re going to need to tool up. Jobs like building wiring harnesses can be tedious and time-consuming, so outsourcing them to this robot wire cutter might be a good idea.

The video below tells the whole tale of this build, which despite the fact that [Maclsk] seems to have put it together quickly from scrap bin parts still looks pretty professional. The business end of the machine is a 3D printer extruder, minus the hot end, of course. A Nano controls the extruder’s stepper to shoot out the right length of wire, as well as the servo that squeezes the snippers. An LCD display and some pushbuttons provide the UI that rounds out the build. Tell it how long and how many, and you’ll be ready to build. We can see how this might be upgraded to strip the wires as well, although getting both ends stripped might be tricky.

Might this component tape-cutting robot from a few weeks back have inspired [Maclsk]’s build? Perhaps, but in any case, both are fun to watch.

Continue reading “Automate Wire Prep With A Robot Wire Cutter” →

Reuleaux Coaster

September 29, 2017 by 15 Comments

What’s better than a cool build? A cool build with valuable advice! Add a few flashy pictures and you have [Martin Raynsford]’s Reuleaux triangle coasters blog post. [Martin Raynsford] wanted to share his advice about the importance of using jigs and we’re sold. He was able to make 100 coasters in a single day and if he’s like us, after number ten, the work gets a little hurried and that is when mistakes are made.

Jig is a broad term when it comes to tooling but essentially, it holds your part in place while you work on it. In this case, a jig was made to hold the coaster pieces while they were glued together. [Martin Raynsford] didn’t need any registration marks on the wood so even the back is clean. If you look closely, the coaster is two parts, the frame and the triangle. Each part is three layers and they cannot separated once the glue dries. If any part doesn’t line up properly, the whole coaster is scrap wood.

This robot arm engraved 400 coasters in a day but maybe you would prefer if you simply had your beer delivered to your new coasters.

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Rushing The Design And Construction Of LED Centerpieces

August 11, 2017 by 7 Comments

‘Dragon Flame’ RGB LED table centerpieces, by [Alex Lao]
Sometimes the most important thing is getting something done.

[Alex Lao] was recently in such a situation. His sister was getting married and he designed, built, and delivered twenty RGB LED table centerpieces in a rush. There were no prototypes made, and when the parts arrived all twenty were built all at once over a single weekend. These table centerpieces are illuminated by RGB LEDs and battery-powered, but have an option to be powered by a wall adapter.

[Alex] helpfully shared some tips on reducing the production risks and helping ensure results in such a limited time frame. His advice boils down to this: reduce the unknowns. For Alex this meant re-using code and components from a previous project — even if they were not optimal — so that known-good schematic and footprint libraries could be used for the design.

From one perspective, the PIC32 microcontroller inside each lamp is overkill for an LED centerpiece. From another perspective, it was in fact the perfect part to use because it was the fastest way for [Alex] to get the devices working with no surprises.

For an added perspective on needing to get production right the first time on a much larger scale, be sure to check out getting an installation made up of 25,000 PCBs right the first time.

Taking A U2F Hardware Key From Design To Production

September 29, 2016 by 17 Comments

Building a circuit from prototyping to printed circuit board assembly is within the reach of pretty much anyone with the will to get the job done. If that turns out to be something that everyone else wants, though, the job gets suddenly much more complex. This is what happened to [Conor], who started with an idea to create two-factor authentication tokens and ended up manufacturing an selling them on Amazon. He documented his trials and tribulations along the way, it’s both an interesting and perhaps cautionary tale.

[Conor]’s tokens themselves are interesting in their simplicity: they use an Atmel ATECC508A specifically designed for P-256 signatures and keys, a the cheapest USB-enabled microcontroller he could find: a Silicon Labs EFM8UB1. His original idea was to solder all of the tokens over the course of one night, which is of course overly optimistic. Instead, he had the tokens fabricated and assembled before being shipped to him for programming.

Normally the programming step would be straightforward, but using identical pieces of software for every token would compromise their security. He wrote a script based on the Atmel chip and creates a unique attestation certificate for each one. He was able to cut a significant amount of time off of the programming step by using the computed values with a programming jig he built to flash three units concurrently. This follows the same testing and programming path that [Bob Baddeley] advocated for in his Tools of the Trade series.

From there [Conor] just needed to get set up with Amazon. This was a process worthy of its own novel, with Amazon requiring an interesting amount of paperwork from [Conor] before he was able to proceed. Then there was an issue of an import tariff, but all-in-all everything seems to have gone pretty smoothly.

Creating a product from scratch like this can be an involved process. In this case it sounds like [Conor] extracted value from having gone through the entire process himself. But he also talks about a best-case-scenario margin of about 43%. That’s a tough bottom line but a good lesson anyone looking at building low-cost electronics.