Matt Marchand Adv. Materials & Processes / 137
PROJECT We will be designing two versions of a Telepresence Unit, with a distinct focus on the materials, processes and technologies involved in manufacturing each.
BRIE F HI STORY OF CO M M UNI CATI ON
500,000 BC : Language
1,500 AD : Yodeling
4,000 BC : Writing
1928 : Television
90’s : Telepresence 2020: Drone-version
3016: ESP 1876 : Telephone
1936 : Videophone
Today
Telepresence Robots - the latest in communication technology. These devices incorporate remote movement control as well as video calling technology to mutually simulate the presence of the caller actually being there. Due to their video conferencing abilities, Telepresence Robots are primarily marketed to large companies for use in an office environment, as depicted with the examples on the right.
T H IS IS T HE CURRENT M ARKET
$15,000
$12,000
$10,000
It leaves a lot to be desired...
$5,000
F IE L D RESE ARCH
F U S I ON D ESI G N Campbell, California, 10/12/16 We got a great opportunity to visit the Fusion Design office and play with their telepresence unit. I was impressed with how the unit moved around quickly and precisely, and I liked the feature it had of stopping before running into things. Right off the bat I was struck with the software side of the unit. The controls were easy and user-friendly, but the interface was quite ugly and not very visually pleasing, which is a shame since that is one users entire side of interaction with the unit. I did not find the design of the unit to be that appealing, although the finish and materials were nice. The only aesthetic element that I genuinely liked was the recharging station. This particular model cost around fifteen thousand, which was way too much in my opinion. Yes, it was very cool that it could drive around, and yes everything seemed to be of good quality, but it did not look like it should cost more than $500. One of the things I took away from our time at Fusion, interacting with the telepresence unit, is that if it is going to cost that much, it better have some damned good features.
M O RE F I EL D RE SE ARCH
AC O RN PRO DUCT D EVE LOPME NT Newark, California, 10/19/16 Our class was able to visit the home office of Acorn Product Development in Newark, California where we got a tour of their products and a presentation of their business. The project Acorn highlighted was their robot, the Robotex Avatar Micro II (as pictured). The robot’s purpose is to work in conjunction with SWAT teams and other law enforcement units as a way to reduce casualties. The unit is a life saving device in that is does things like breaching or bomb disposal that are typically extremely dangerous. Due to the rough environment it is operated in, it was fascinating to learn the rigorous user experience & manufacturing considerations that went into the robots design. This research trip made me appreciate the amount of work that goes into designing something that people’s lives literally depend upon.
T H E PROBLE M Current Telepresence Robot designs neglect the functions and aesthetics of a home market.
T HE G OAL Design a telepresence unit that fits seamlessly into the home, while incorporating functions that assist and improve everyday life.
CO N SI D E RATI ONS Some quick definitions: “Telepresence” - The idea of being visually present during communication. “Robot” - A machine for completing tasks. “Telepresence Robot” - A machine used to be visually present during communication.
EN V I R ONM E NT Designing it to blend into any environment through a use of natural materials like wood and glass. Although the unit would be large, at about 62” high and about 50 lbs, it would also be thin and could be against the wall easily so to not be in the way. For the high volume, less expensive model, I will likely be using some for of plastic to reduce manufacturing costs, but we’ll get into all that later.
U N C A N NY VAL L E Y One thing to be careful of when designing a robot, is to not make it too human like. You know how sometimes robots that look like humans are creepy? That’s called an uncanny valley. Robot that looks like square? Not creepy. Robot that looks like a robot wearing a human face? Creepy as hell. My goal is to design a telepresence robot that looks more like furniture, so that it blends into the home and doesn’t give everyone nightmares. Beep boop blorp.
P R I M A RY U S E The primary use would be people who want to be in closer, more personal contact with ones they communicate with regularly, but also get more out of the robot than just the telepresence. Ideally the unit would be used all day long from assisting with workflow to providing an entertainment platform.
FE AT U RE S Ideally this unit would feature full touch screen capabilities and see through glass so that it blends into your home (Or in the less expensive, high production model, a one way mirror with a tablet behind). Both would be running an android OS system that would function like a large tablet. The camera would be a iPhone unit, so very crisp resolution, and the speakers would be JBL to produce very good sound, for more than just video calling, but for music or movies too. The batteries in the base would allow the unit to be wireless, and the unit would be able to move around all types of floors due to the tread base.
MI S C . Future Scenarios: One day this unit could replace TV's and tablets in the home. Competitors: TV’s, tablets and other mobile devices that allow the user to engage in media and communicate visually with others. - High volume goal for under $2k, like the price of a very nice television. 500k units. - Low volume goal for about $25k - like a piece of functional art. 500 units.
As mentioned earlier, I’ll be designing two types of telepresence units. One low volume, one high volume. It’s important to remember which one is which. This should help.
LOW VOLUME P E RS O N A I
/
E XPE NS I VE
HIGH VOLUME P ERS O N A I I
/
I NE XPE NS I VE
PERSON A I
Executive traveling internationally. Wants a larger presence at home with their spouse and children. Low-Volume / Unique Materials / Bespoke / Expensive
PERSON A II
Young event coordinator in a new city. Wants a more personal way to communicate with clients. High-Volume / Common Materials / Inexpensive
CONCEPTS
COMPONENTS These are the parts that will make up the telepresence unit. They help decide the body shape
1
Vex Robotic Tank Threads (x2)
12" x 1" x 30"
$200
2
AmpFlow M27 150-P Motor (x2)
2.7" x 3.9"
$400
3
Nuro Rechargeable Battery (x4)
7.5" x 3" x 3"
$400
4
Collermaster Fan (x3)
2.5" x 2.5" x .6"
$90
5
Nuro Charging Port
12" x 4" x 1"
$30
6
IR Sensortech
10" x .5" x .5"
$60
7
JBL Bass Speaker
4" x 4" x 4"
$50
8
Apple iPhone 7 Camera
.2" x .2" x .2"
$60
9
Qualcom Computer Chips (x3)
.1" x 4" x 2"
$120
10 JBL Mini Speaker (x2)
5" x 1" x .5"
$60
11 Toggles and Dials
-
$ 50
12 OLED Screen (Not Pictured)
TBD
$5,000 +
13 Mirror (Not Pictured)
TBD
$ 40
8
10
11
9
7
3
6 5
2
1 4
H IGH VO LUM E / LOW TECH
" M IRR OR S CRE E N" Simply put: A touch capable mirror with device behind.
LO W VO LUM E / HI G H TECH
" O LE D G L AS S" Simply put: A touch capable see through glass screen.
H IGH VO LUM E CONCE PTS Touch Screen / Mirror Surface / Inexpensive
5
6
7
8
9
10
LO W VO LUM E CONCEPTS Touch Screen / Transparent / Expensive
1
2
3
4
5
6
As a recap, in the last few pages we considered the personas for low and high volume, some early concepts, and then the components I selected. Using these components I came up with 20 initial directions for high and low volume.
For the rest of this book we'll be getting into details and specifics. We'll start by exploring some low-volume concepts using different manufacturing methods.
If materials and processes make you sleepy feel free to skip to the end to see the pretty pictures
CO N C EPT / FORM E D Sheet metal: A press brake is a machine tool for bending sheet and plate material, most commonly sheet metal. It forms predetermined bends by clamping the work piece between a matching punch and die. Bending process.
CO N C E P T / AD D ITI VE Carbon fibers are usually combined with other materials to form a composite. When combined with a plastic resin and wound or molded it forms carbon-fiber-reinforced polymer (often referred to as carbon fiber) which has a very high strength-to-weight ratio, and is extremely rigid although somewhat brittle.
CO N C E P T / CAS TI NG Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term “sand casting� can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries.
C O N C E PT / S UBTRACTI VE Wood carving is a form of woodworking by means of a cutting tool in one hand or a chisel by two hands or with one hand on a chisel and one hand on a mallet, resulting in a wooden figure or figurine, or in the sculptural ornamentation of a wooden object.
C O N C E P T / PRI NTE D 3D Printing, also known as additive manufacturing (AM), refers to processes used to synthesize a three-dimensional object in which successive layers of material are formed under computer control to create an object. Objects can be of almost any shape or geometry and are produced from digital model data 3D model or another electronic data source.
SELECTION
FO R ME D
A D D IT I VE
CAS T
PRI NTED
SU BT RACTI VE / D I RE CTI ON
D F M A - D E SI G N FOR M A N U FACTURI NG & ASSE MBLY DFMA is an essential process that combines “Design for Manufacturing” and “Design for Assembly” to create a product that is easily made and built. By designing a product with DFMA in mind, the smoother, more seamless process can help reduce overall costs and difficulties. I will be using these guidelines to refine my two designs.
R E DU C E PARTS Reducing the total parts is an efficient way to reduce costs on both the manufacturing and assembly side. This can be as simple as less inventory and shipping to something as complex as designing the part to be made in a single mold, casting or injection.
MO DU L AR D E S IG N Modular parts assist in the manufacturing process because it can simplify processes like testing which can be costly, as well as design flexibility. Rather than redesigning entire units, the modules can be altered as needed, saving time and money.
STA NDA RD IZ AT IO N Utilizing standard components, also called “off the shelf� or OEM, can save manufacturing costs. Because these parts are made in such large quantities they are often quite inexpensive , they have had all the quality issues solved, and they are available in large quantities.
MU LT I -F U N CTIO N AL If a part can be used for more than one function, that is a cost saving opportunity. This can be as simple as a structural member of the product also doubling as a heat sink, or an element that can help guide a part into place.
MU LT I -U S E Some parts can have multiple uses across the same product, or even different products. These parts can reduce manufacturing costs by simply doing more than one thing. These parts become part of a family and follow set steps to increase assembly speed across a spectrum of products.
FA B R I C AT IO N Choosing a material and fabrication process that do not require as much finishing or detail work. If excess processes like painting are needed they can drive up part costs and slow down the overall production speed.
CON S I STE N C Y Utilizing the same fasteners across the design will safe part costs because manufacturers would be able to buy in bulk, as well as assembly costs because less tooling or stations would be needed, since the fasteners would all use the same bits. Self-tapping and chamfered screws are best for improving placement success.
TO P - DO W N AS S EMBLY If the part has to be rotated for every fastener or piece during the assembly process, it will slow things down significantly. This is why minimizing the assembly directions are so important. Ideally, things would be installed top-down, with the assistance of gravity and consistency.
FAC I L ITAT E IN S E RTI ON Also known as maximizing compliance, this process saves errors on the assembly side, by increasing the probability that the parts go where they are designed with limited interruptions. If done poorly, parts with poor compliance will get snagged or broken when being inserted into place.
MI NI M IZ E H AN D LI NG Much like the top-down assembly, minimizing the handling is an assembly opportunity. Rather than flipping parts around and struggling to connect things, a well designed product takes everything into account, and makes it so the overall handling is reduced, which saves time and money on the assembly.
C ONCLUS I ON If the manufacturing and assembly are taken into account during the design phase, there will be savings of time, errors and costs across the board. DFMA simplifies and smooths out the wrinkles of production
LOW VOLUME
D E TAIL S / SE CTI ON VI EWS
Camera & Speaker bar inserted into the back of the hollowed out wood frame. Camera and speaker modules built into aluminum frame along with wiring, screwed into back of wood.
Charging Port has knobs and a plug to insert the power plug for the rechargeable batteries. This would be made from a die cast aluminum part. Attached by adhesive.
CNC Base to provide extremely accurate housing for the internal components. Components inserted into frame from below. - Components fastened with (16) Phillips .4 x 2mm wafer head screws
Hand Carved main body from a unique, fallen tree. Each one would be completely unique and custom done by artisanal craftsman.
CO MPONENTS 1.1 Tread Set 1
Rubber
Mobility
1.2 Tread Set 2
Rubber
Mobility
2
Wood Frame
Hardwood / Maple
For aesthetics, stability
3
Metal Frame
Aluminum
Run wires inside
4
Charging Port
Aluminum
Controls, recharging
5
OLED Screen
Glass / Electronics
Presentation
6
OLED Driver
Electrical components
Running OLED Screen
7
Module A
Photo & Audio chip
Run photo & audio
8
Module B
Bluetooth chip
Run wireless control
9
Module C
Computer chip
Run motors and power
10 Battery 1
Rechargeable battery
Power
11 Battery 2
Rechargeable battery
Power
12 Camera
iPhone camera module
Video capability
13 Audio
Speaker / Microphone
Audio capability
14 Fasteners ( x 20 )
Phillips M2 x .4 x 2mm
Fastening
LO W VOLUM E S E CO N DA RY PROCE SSE S I - BACK W I RI NG BAR II - CO M PONE NT HOUSI NG III - BA S E HOUS I NG
S E C O N DARY PROCE SS I Sand cast aluminum, for the rear of the telepresence unit. This would provide a housing for the electronic wiring going to and from the audio visual components up top and back down to the modules in the base. I am using this process because sand casting provides a great looking almost-rough piece when semi-finished. This aesthetic will match well with the wood of the body.
Sand mold is made creating a cavity inside based on an impressed mold of the desired form. Due to the consistency and fine grain of the sand very accurate details are possible, although draft and undercuts are still an important consideration.
Molten aluminum is poured into the holes, filling the cavities. The design must take into account the sprues and risers to ensure the molten metal flows evenly and that the final product does not have any gaps or weak areas.
Break away the sand mold after the metal has cooled. This reveals the unfinished form. The sand can be collected and re-used for future molds.
Finishing the form is important as every sand cast mold has sprues and risers where the aluminum was poured in and risen up. These can be removed and the bar finished. For this form it will be a little rough for a more natural aesthetic.
S E CO N DA RY PROCE SS I I Laser cut and bent sheet metal could be considered a two part process, but when done well it can be a seamless process. First the machine laser cuts out a “flat� design for the box and then the press brake is used to bend the sheet metal pattern into a 3-dimensional form. In the case of the telepresence unit it is a great process to make a housing for the internal components.
Designing the cut is an important step since the bending process is completely dependent on if the design in foldable. Many mockups are made to ensure the design is functional.
Laser cutting the part takes more or less time depending on the thickness of the sheet metal as well as the power of the machine. For a highvolume design turret punching would be a better process.
Bending the part into the final form is done using a press brake. This machine uses specific jigs to create angles in the sheet metal by applying force in one direction. Rounded forms are do-able but take more time.
Finishing the part involves grinding down edges, welding needed areas and even powder coating. While some of these processes can be for aesthetic purposes, they also reduce the sharp edges.
SECONDARY PROCESS III CNC is a process that is perfect for the base because it allows for a lot of precise cuts to be made while still keeping the overall form complete. CNC for the base would take a lot of special tooling since the part is so large and requires so many different size bits. However since this is the low volume design it would be acceptable for the price range.
Designing the CNC is important since the body has to house all the components tightly. This must also take into account the sheet metal component shape so they do not clash.
CNC cutting would involve many times to change the tools and bits but if the machine is fancy enough it can swap bits on the go to reduce the overall time and in the end save money.
Base CNC would have the final holes drilled in to accommodate the sheet metal component housing attachment. By doing screws instead of adhesive the parts could be removed for repair easier.
Finishing the inside of the CNC shape would involve some sanding but for the most part it would be done and ready for the install of components.
HIGH VOLUME
D E TAIL S / SE CTI ON VI EWS
Fasteners designed to be quick and inexpensive and include snap fastening plastic components together, and adhesive attachment between the mirror and the compress molded plastic frame.
Tablet loading door is built into the back and compatible with all types of tablets, phones and other touch screen devices. Reduces overall hardware and component cost and allows owners to utilize their own products.
Underside is molded to fit the internal components perfectly, while protecting them from the floor. Initial tooling would be pricey, but would save costs on a large scale by having a single inexpensive snap-in piece.
Bumper base is a snap fit to the main body. This continuous piece is made out of a separate injection mold. This reduces the overall body parts to 4 parts. Main body, device door, one way mirror, and base plate.
CO MPONENTS 1.1 Tread Set 1
Rubber
Mobility
1.2 Tread Set 2
Rubber
Mobility
2
Frame - Upper
Injection Molded Plastic
Structure, housing
3
Frame - Lower
Injection Molded Plastic
Structure, housing
4
Charging Port
Die Cast Aluminum
Structure
5
Mirror
Glass & Polished Aluminum Presentation
6
Touch Overlay
Electrical component
Finger Control
7
Module A
Audio chip
Run audio
8
Module B
Bluetooth chip
Run wireless control
9
Module C
Computer chip
Run motors and power
10 Battery 1
Rechargeable battery
Power
11 Battery 2
Rechargeable battery
Power
12 Audio
Speaker / Microphone
Audio capability
13 Device Door
Injection Molded Plastic
Feature
14 Fasteners
Snap fit, adhesive
Fastening
H IG H VOLUM E S E CO N DA RY PROCE SSE S I - RE AR F RAME II - BAS E PL ATE III - BU M PE R
S E C O N DARY PROCE SS I Injection molding, for the frame of the telepresence unit. This piece would support the mirror surface at front, while providing a way to get wires up top through the body. This is a good process for high volume manufacturing. Since this would be a large piece the tooling would be expensive at first, but as long as it is produced at a large scale the tooling price margin becomes tiny.
Combining three pieces in the design would mean using a three part mold to account for undercuts and features This tooling would cost a lot, but be worth it for such a high volume injection mold.
Tooling the mold with precision is extremely important to the final design an appearance of the parts. The rear frame is the largest of the parts and would require the largest and most expensive tooling.
Snap fastening is an inexpensive and quick solution to connecting multiple parts for high volume designs. The choice for this design is a non-removable snap because this is supposed to be a “cheaper to just throw away� design...
Features of injection molding include sprues and ejector pin marks. Ribs are needed to strengthen the part and are built into the design along with draft angles.
S E CO N DA RY PROCE SS I I Compressed Molding is a great process for the base plate at the base of the unit. Due to the components and proximity to the floor, this needs to be protective as well as simple. Compressed pressing takes heated plastic and using a die and tooling presses a form into place. This process is used for many high volume products since it is so simple and quick to form the parts.
Designing the skid plate is important since all the components need to fit tightly when fastened after the forming process. This must also take into account the snap fasten connections.
Details that would normally be done with a turret punch can be molded right into the form. For example, the wheel slots and charge port openings.
Compressed molding the plastic involves high pressure to get a consistent form. This shallow design does not require the plastic stock to overstretch so it would not lose structural integrity. Takes into account draft angles for release.
Fastening the skid plate to the die cast base simply uses snap fasteners from the upper molded unit to complete the base. This will be secure but nearly impossible to reopen once closed.
S E C O N DA RY PROCESS I I I Die casting is one of the most efficient high-volume metal manufacturing processes. In the design for this telepresence unit the weight has to be taken into account since the mirror is heavy and additional weight is needed at the base. The die cast metal would also add an additional aesthetic to the design that is otherwise plastic on the exterior.
The base / bumper adds needed weight for stability as well as a tougher surface than the injection molded plastic. Would be a ring around the base, surrounding the internal components.
Forming the part is done with a die-cast mold. It operates similar to injection molding but with molten metal, in this case aluminum. Design incorporates 10 degree draft on all edges.
Finishing the die cast part involves sand blasting the part, but the majority of the texture comes from the mold itself. This ensures a constant texture across all the parts, while trying to replicate the roughness of the original design.
Fastening systems are molding into the part. Specifically snap fits for the top housings and snap-in punch holes for the skid plate underneath. (One hole in each corner)
LO W VOLUM E
H IG H VOLUM E
O KAL A E COD ESI G N S T RATE G Y G UI D E
“eight steps to reduce the ecological impact of products”
1
3
5
7
Innovation
Reduce Material Impacts
Rethink how to provide the benefit. Design flexibility for technological change. Serve needs provided by associated products. Create opportunity for local supply chain. Mimic biological systems. I will use innovation by providing the product as a service.
Avoid materials that damage human or ecological health. Avoid materials that deplete natural resources. Minimize quantity of materials. Use recycled/reclaimed materials. I will be using renewable resources.
2
Manufacturing Innovation
Reduce Distribution Impacts
Minimize manufacturing waste. Design for production quality control. Minimize energy use in production. Use carbon-neutral or renewable sources. Minimize number of production steps. I will seek to minimize number of components/materials.
Reduce product and packaging weight. Develope reusable packaging systems. Source or use local materials and production. Use lowest-impact transport system. I will reduce product and packaging volume.
4
Reduced Behavior Impacts
System Longevity
Design to encourage lowconsumption user behavior. Reduce energy, water and material consumption during use. Seek to eliminate toxic emissions during use. I will design for carbon-neutral or renewable energy.
Design for maintenance and easy repair. Design for re-use and exchange of products. Create a timeless aesthetic. Foster emotional connection to product. I will design for durability.
6
Transitional Systems
Optimized End of Life
Design upgradeable products. Design for second life with different function. Design for reuse of components. I will be Using reclaimed materials.
Integrate methods for used product collection. Design for fast manual or automated disassembly. Design around a recycling business model. I am using recyclable non-toxic materials that provide the ability to biodegrade.
8
MATERIALS SELECTION Researching the exact materials for specific parts, across the low and high volume designs.
LOW VOLUME
HIGH VOLUME
LO W VOLUM E I Looking for a rugged, sturdy, metal aesthetic
S E L E CTI O N
“M ETA P O R ”
“ALUS I ON”
“E CO-MG ALLOY”
Price : III
Price : II
Price : III
Durable: : II
Durable: : I
Durable: : II
Sustainable: II Metapor (MC# 6066-01) is an aluminum/polymer composite that is air permeable. Aluminum granules are bonded together with an epoxy resin in such as way as to maintain microporosity through the thickness of the part. The parts may be cast into any shape which is helpful for the application, but it is too weak to be in the home.
Sustainable: III Alusion (MC# 3581-01) is produced by injecting air into molten aluminium, which contains a fine dispersion of ceramic particles. These particles stabilize the bubbles formed by the air. I ordered samples of this material but it was just too porous and weak to be a viable option.
Sustainable: III Eco-Mg Alloy (MC# 7040-02) is a magnesium alloy, which is the lightest type of structural metal. I chose this material because It is strong, can be cast easily and is sustainable, making it a really good choice for the telepresence unit. Sustainable, lightweight AND strong? That is a winning combination.
LO W VOLUM E ME TAL I I Looking for a thin, lightweight metal for the bottom.
S E L E CTI ON
“ PU RE + FR E E F O R M ”
“S ONOPE RF ”
“HI S HI METAL”
Price : II
Price : III
Price : II
Durable: : III
Durable: : III
Durable: : III
Sustainable: I Pure + Freedom (MC#743501) offers bespoke printed metal sheets that could be laser cut. A durable polymer coating is applied directly onto the aluminum, which allows for different appearances. Since it is on the bottom appearance is not important, but durability is.
Sustainable: II Sonoperf (MC# 7598-09) is a sound absorbing perforated metal sheet with micro slits, for sound, reverberation and heat absorption. I chose this material because It meets thermal requirements, and due to being available in aluminum and anodization, makes it very durable. This is the perfect low volume material.
Sustainable: I Hishimetal (MC# 4822-02) uses laminated stainless steel with polymer film faces. It offers high durability and workability, allowing for high variability in structure through working processes like punching, forming or bending. It’s durability is good since it will be undergoing some of the most stress of all the unit parts.
LO W VOLUM E WOOD Wood is awesome. I want to use a very sustainable hardwood.
S E L E CTI O N
“ RE C L A IME D W O O D ” Price : II
“ B A M BOO L AMI N ATE ”
“F S C H ARD W O O D”
Price : IIII
Price : IIII
Durable: : IIIII
Durable: : IIII
Durable: : IIIII
Sustainable: IIIII
Sustainable: IIIII
Sustainable: IIII
Viridian reclaimed hardwood (MC# 7426-01) is made from FSC® recycled 100% postconsumer reclaimed weathered lumbers. Reclaimed from old fence boards, dismantled barns and truck decks, the wood has been exposed to years of weathering to create a genuine patina. Very sustainable. Very unique.
Laminated Bamboo Boards (MC# 7557-01) feature high strength and durability. They are 100% renewable and biodegradable and unlike hardwood, bamboo can be can be harvested every three to five years. It is natural anti-bacterial, water-resistant and extremely durable. Really good option
The Forest Stewardship Council (FSC) is an international nonprofit organization established to promote responsible forest management. The FSC does sets standards on hardwoods labeling them as eco-friendly. Using FSC certified hardwoods ensures a wide and sustainable material selection. This is the best and most versatile option for customers.
H IG H VOLUM E P L AS TI C On the look out for a sturdy, recycled plastic.
S E L E CTI ON
“BIO-RES P L A”
“PL MS 6040”
“BI OBAS E D PO LYM ER”
Price : II
Price : II
Price : II
Durable: : II
Durable: : III
Durable: : II
Sustainable: III
Sustainable: III
Sustainable: III
Bio-Res PLA (MC#7504-03) is derived from renewable feedstock, they do not use toxic compounds during production, they sequester carbon dioxide and they can replace a portion of traditional oil-based resins. This process, though sustainable, does not make an aesthetically appealing or durable enough material.
PLMS6040 (MC# 7040-02) is made in the US, injection moldable, biodegradable, compostable and derived from renewable resources like corn starch or sugarcane. It has a good smooth surface that can be colored and will look great with the unit. I like that this material fits all my criteria like sustainability and aesthetics.
High Impact Biobased Polymer (MC# 7267-01) is a strong, high-impact resin made from renewable resources including corn. It is compostable and compared to PLA has improved mechanical properties, ductility, and strength. The PLA of this material is sourced from postindustrial scrap and could be a “green” alternative to PVC.
H IG H VOLUM E REF L E CTI VE Find an inexpensive transparent material as a mirror surface.
S ELECT I O N
“ ULT RA LIT E M I R R O R ”
“D E CORF LOU”
“ACRYL I C MIRRO R”
Price : II
Price : II
Durable: : III
Durable: : III
Durable: : III
Sustainable: II
Sustainable: II
Sustainable: II
The Ultralight Mirror (MC# 7592-01 ) is a lightweight thermoplastic mirror offering a highly reflective image quality. The sheets are optically clear, have good impact resistance and can be formed to specific dimensions. Due to it’s simple design and light build it is the perfect material for the mirror.
Decorflou mirror (MC# 449107) is a satin finished, etched mirrored glass designed to reflect light. It is has high impact resistance when tempered or laminated, high light transmission, and is scratch resistant on etched surfaces. It is heavy though which would put the unit off balance.
Price : I
The clear acrylic Fabback mirrors (MC# 7391-02) have 10 times the impact resistance and 50% reduced weight in comparison to glass mirrors. Unlike regular glass, it does not shatter into small pieces when broken. It can also be machined, drilled and cut easily and is available in a variety of translucent and opaque colors. Variety is good, but it looks too cheap.
H IG H VOLUM E ME TAL This has to be progressive die stamped, so thin metal is ideal.
S E L E CTI O N
“S ONOP E R F ”
“ TOS OL BOND ”
“HI S HI METAL”
Price : III
Price : II
Price : II
Durable: : III
Durable: : II
Durable: : III
Sustainable: III
Sustainable: III
Sustainable: II
Sonoperf (MC# 7598-09) is a sound absorbing perforated metal sheet with micro slits, for sound, reverberation and heat absorption. It meets thermal requirements, and due to being available in aluminum and anodization, makes it very durable. Unfortunately it is too expensive for this application.
Tosolbond (MC# 6793-01) is an aluminum composite panel made of aluminum sheets and a low-density polyethylene. Treated with a polyester-based coating to protect it from possible corrosion problems that might arise from being on the ground getting scratched or damp.
Hishimetal (MC# 4822-02) uses laminated stainless steel with polymer film faces. It offers high workability, allowing for high variability in structure through working processes like punching, forming or bending. I chose this material because it’s price and durability make it the best choice. Especially the durability since it’s on the floor.
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M A N U FACTURE R SE L E CTI ON PRO CE SS / CRITE RI A
Picking the right manufacturer is an essential step of any good design. This selection process begins at the design, and depending on the parts and pieces, points towards a specific manufacturing direction. On the next few pages we will be considering Process, Quality, Price, Capacity, and Geography, but before we look at those, here are some things to consider when picking a manufacturer:
1 . W H O YO U KNOW Done a project with a manufacturer before? Did it come out great? Awesome, there you go. As you grow in the industry and meet people, personal relationships will become important and so will good work. Often times the “good work� costs more up front but can save money in the long run.
2 . RE CO M M ENDATI ON New to a certain type of manufacturing? Ask a colleague who they use. Again, personal relationships in the industry can be very important.
3 . T RAD E S H OWS Trade shows can be a great way to meet manufacturers and develope relationships. The shows also provide a way to see their goods first hand, as opposed to word of mouth or through photos online. Pick up the parts, ask questions, and learn.
4 . M ANU FACTURE RS RE P Manufacturers representatives make it their business to know people. You can rely on their experience and connections if you need more options. An added bonus of these representatives is that they are free to use. Be nice though, they have feelings too.
5 . RE S E ARCH When all else fails, look it up. The internet is a great source, although it can lack a personal touch, as well as a physical touch for part quality etc. Thomas Guide is another research tool that can assist the manufacturer selection process.
LOW VOLUME M ANU FACTURE RS
S AND CASTI NG
S E L E CTI ON PROTOC A ST I N G I NC .
GE NE RAL F OU ND RY
RU I CAN CAS T ING INC.
Niles, Ohio
Fremont, California
Yulong, China
Cost: Med
Cost: Medium
Quality: High Capacity: High “Our company manufactures metal components in prototype and low-volume production quantities. Whether it is 1 or 5,000 parts, we deliver functional components and assemblies that meet your delivery schedules. We can assist you in producing prototypes all the way up to production die castings.”
Quality: Very High Capacity: Medium “At General Foundry Service, “We Pour Molten Metal into Useful Shapes in a Precise, Economical, & Timely Manner using Precision Sand Casting. Expertise in CNC Machining, Finishing, Assembly and General Foundry’s service quality, engineering, and on time deliveries keep our customers coming back. “ I chose General Foundary for the sand cast arm because I have met the guys, I have seen their work firsthand, and know that they are worth it, certainly for the low volume price point. I am happy to give them work.
Cost: Low Quality: Low Capacity: Very High “Ruican Casting is a professional supplier for casting and machined part which is widely used for all kinds of processes. With more than 320 employees in our company now and about 33 technicians from medium to senior, our large facility is capable of meeting all size demands.”
LOW VOLUME M ANU FACTURE RS
L AS E R CUT TI NG
S E L E CTI O N META LWER K S , I NC .
RE I CH ARDT
PRE CI S I ON M ETAL WORKS
Marysville, Washington
Stuttgart, Germany
Campbell, California
Cost: High
Cost: High
Cost: Medium Quality: High Capacity: High “Our prime speed laser delivers precise and rapid fabrication with out the need of tools! Great for precision sheet metal prototyping and production runs because the cost is drastically reduced by not having to build tools“
Quality: Very High Capacity: High “Our In house manufacturing does not only mean enhanced precision & flexibility but also a significant increase in productivity. The improved focus on targets and economy achieved in this way directly benefits our customers.”
Quality: Very High Capacity: Medium “Precision Metal Works provide the quality service with friendly support for prototype, light production, aluminum spot welding, and machining. No job is big or too small for us.”
I chose Precision Metal Works for my laser cut metal parts because not only are they very local but they have good reviews and are capable of making the low volume parts I require.
HI GH VOLU ME M ANU FACTURE R S
I NJ ECTI ON M OLD I NG
S E L E CTI ON W PL A ST I C S I N C . Fremont, California
Cost: High Quality: Very High Capacity: Low “Kightsbridge Plastics, inc. has been an industry leader since 1982 in the field of innovative mold making and the production of intricate, close tolerance tooling and plastic injection molded parts and components for a wide spectrum of industries and applications.“
D I NE S OL PL AS TI CS I NC.
E CO MOL D I N G CO.
Niles, Ohio
Shenzhen, China
Cost: Med
Cost: Low
Quality: High
Quality: Low
Capacity: High “Dinesol gets it done! With a modern plant and equipment, consistent and aggressive people with years of experience, quality, financial stability, and capabilities to take ideas to finished products, they are your plastics solutions partner.“
I chose Dinesol for my injection molding manufacturing because they are a US based company, that is able to produce a large amount of units, for a lower price compared to other. Their part quality is also great.
Capacity: Very High “Eco molding offers plastic injection molding services and specializes in various plastic moulds for automotive, home appliances, electronics ,as well as general industrial OEM applications. Mission is to be professional, trustworthy and creative toolmaker and injection molding supplier.”
HI GH VOLU ME M ANU FACTURE R S
PROG . D I E STAM PI N G
S ELECT I O N J L PR EC I S I O N
H P L S TAMPI NGS , I NC.
J I NFANGYUAN CNC M ACHI NE CO
Santa Clara, California
Springfield, Illinois
Yangzhou, China
Cost: Medium Quality: Very High Capacity: High “We support our customers from the early stages of R&D, first article validation, pilot production, all the way through mass production. We control all steps of the production process, from manufacturing, plating, painting, assembly, and inspection.“
I chose JL precision for my progressive die stamping manufacturing because they are US based and for the price they are able to produce large, high quality quantities.
Cost: Medium Quality: High Capacity: High “Innovative tooling methods & laser cutting advances allow us to blend our custom metal stamping expertise with sheet metal fabrication technology, resulting in complete unlimited metalforming service previously unheard of in our industry. We do it all. “
Cost: High Quality: Very High Capacity: Low “Jiangsu Jinfangyuan CNC Machine Company Limited, located in the high-tech zone of Yangzhou City, is the largest CNC plate processing facility manufacturing base in China, the products have been exported to all of the world.”
LO W VOLUM E COS T
500 k
COST PER UNIT
50 k
20 k
15 k
10k
5k
2k 0
1
10
100
1,000
10 k
100 k
N U M BER OF UNITS : Target amount
1m
NUM BE RS
DATA INPUT Sand Casting Tooling
$
15,000
$
15,000
Laser Cutting $
-
OLED Parts
$
10,250
$
Assembly
$
400
$
AV
8,000
$
Hourly Wage
Margin
-
Units
Wood Carving $
-
-
Movement 500
$
500
-
$
Power
$
-
$
-
$
Wood 500
$
-
$
-
Metal Arm 500
$
250
$
-
Hours / Unit
50.00
8
55%
1
10
100
1,000
10,000
100,000
1,000,000
10,000,000
Tooling
$
15,000
$
1,500
$
150
$
15
$
2
$
0.15
$
0.02
$
0.00
Components
$
10,250
$
10,250
$
10,250
$
10,250
$
10,250
$
10,250
$
10,250
$
10,250
Assembly
$
400
$
400
$
400
$
400
$
400
$
400
$
400
$
400
Unit Cost
$
25,650.00
$
12,150.00
$
10,800.00
$
10,665.00
$
10,651.50
$
10,650.15
$
10,650.02
$
10,650.00
Unit Price
$
57,000.00
$
27,000.00
$
24,000.00
$
23,700.00
$
23,670.00
$
23,667.00
$
23,666.70
$
23,666.67
After 100 units the cost flattens to about $10,800 The difference between 100 units and 1,000 units is small considering, and since this particular unit would be designed for widespread sales, this slightly reduced price gives a slight advantage. In the end though, if there was a question of sales possibility, 10,000 units would suffice with only a minimal price hike.
H IGH VOLUM E COS T
400 k
COS T PER UNIT
50 k
20 k
15 k
10k
5k
1k 0
1
10
100
1,000
10 k
100 k
N U M BER OF UNITS : Target amount
1m
NUM BE RS
DATA INPUT Injec. Molding
P.Die Stamping $
Tooling
$
400,000
$
Components
$
900
$
Assembly
$
5
$
350,000
50,000
Movement
-
Units
$
Batteries
500
$
Hourly Wage
Margin
-
-
$
Electronics
150
$
-
$
100
$
Misc
50
$
-
$
100
$
Mirror
-
$
-
$
-
-
-
Hours / Unit
10.00
0.5
45%
1
10
100
1,000
10,000
100,000
1,000,000
10,000,000
Tooling
$
400,000
$
40,000
$
4,000
$
400
$
40
$
4.00
$
0.40
$
0.04
Components
$
900
$
900
$
900
$
900
$
900
$
900
$
900
$
900
Assembly
$
5
$
5
$
5
$
5
$
5
$
5
$
5
$
5
Unit Cost
$
400,905.00
$
40,905.00
$
4,905.00
$
1,305.00
$
945.00
$
909.00
$
905.40
$
905.04
Unit Price
$ 728,918.18
$
74,372.73
$
8,918.18
$
2,372.73
$
1,718.18
$
1,652.73
$
1,646.18
$
1,645.53
After 100,000 units the cost flattens to about $900 The difference between 10,000 units and 100,000 units is only fifty dollars, and since this particular unit would be designed for widespread sales, this slightly reduced price gives a slight advantage. In the end though, if there was a question of sales possibility, 10,000 units would suffice with only a minimal price hike.
C O S T COMPARI S ON
400 k
COS T PER UNIT
50 k
20 k
15 k
VO LUM ES
10k
LO W
5k
HIG H
1k 0
1
10
100
1,000
10 k
100 k
N U M BER OF UNITS
1m
C ONCLUS I ON
To get a visual interpretation of the data I had to first make a spreadsheet, figure out how to make it work, and then figure out how to calculate margins and other fun things like that. Long story short it took a while and I pulled a lot of my hair out, BUT I did end up with some great data that I could use to graph. It was through this graph that I was able to compare the Low and High volume telepresence units. The Low Volume units are the more custom ones, which relied on less upfront tooling but more expensive labor and components. This resulted in a lower single unit cost, but once it got over 100 units, a much higher unit cost (about $12,000). The High Volume units are the ones that would be sold in places like Target and require a mass production approach. Setting up the tooling would be expensive, which is why the single unit price was so steep. Eventually though, due to low cost on components and labor, the High Volume units ended up costing much less once they got over 10,000 units. Seeing the two costs side by side made much more sense and helped me visualize the market applications of each and the volumes required to make them viable. As shown in the Low Volume data, a margin of 55% would be added to the total cost, making a unit price at 100 units about $24,000 As shown in the High Volume data, a margin of 45% would be added to the total cost, making a unit price at 100,000 units about $1,650
BRANDING LO W VOLUM E
METHODS Looking for an elegant and unique solution
PRINTED: Hand Painted/Stenciled Airbrushed UV Printing Hydro Printing APPLIED: Etched Inlay Wood Burning Nameplates: Cast metal Nameplate Chem. Etch. Nameplate
INTEGRATED: Cast Embossed/Debossed Laser Cut Texture Machined Two shot molding OTHER Grown Metal Stitching Embroidery Backlit Corroded
M ACHI NED Machining the brand onto the cast metal in this case simply means grinding down the rough gritty exterior until it’s flat, revealing the shiny solid metal below. This would provide a nice two toned contrast and really make the logo pop out.
CAS T Casting the branding along with the rest of the metal is a very integrated way to include branding. This branding method could provide a very seamless and simple look that would match the rest of the design while also not being another step in the manufacturing process. Must take into account draft angles.
I NL AY
S E L E CT I O N
Inlaying is a beautiful way to incorporate branding into a form. It involves the metal being milled out, and the wood cut to fit. To do this right would require a specialized craftsman and would be quite expensive per unit. Because it would take a lot of skill and precision while providing a very unique look, I chose this for my low volume unit branding.
BRANDING H IG H VOLUM E
METHODS Looking for a simple and inexpensive solution
PRINTED: Silkscreen Spray painted Pad printing
INTEGRATED: Stamped / Die Punched Texture change Two shot molding Injection Molding
APPLIED: Stamping Glued on Labels Electroforming Sticker Dome Label
OTHER Embroidery
S TI CKER Stickers are a quick and easy way to apply branding to just about any surface. Issues can arise through time as stickers can peel or have their edges tattered. This solution is just not integrated enough for my liking.
PAD PRI NTE D Painting the logo on using the pad painting process can be a very inexpensive way to brand the unit. If done well the paint would not chip and could have a nice look to it, but it is still not integrated enough for my liking.
MOLD E D If the mold used to injection mold the part has the logo integrated, it can be an extremely inexpensive branding feature, especially as the number of units increases. Even better the logo is completely part of the product and will never peel off. I chose this method because it will be cheap, work well, and look great. S E L E CT I O N
M E TAL
G L ASS
CMF / LOW
WOOD
ME TAL Anodized Aluminum
Bright and shiny would not fit the aesthetic.
Cast Steel
Galvanized Steel
I love how course and raw the material looks. Very rugged.
Too manufactured looking.
G L ASS Dark Reflective
Light Grey Frost
Heavy Frost
Too dark. Couldn’t see anything.
I chose this because it gives the screen a little more presence than if it were clear.
Too frosted, couldn’t see through it.
WOOD Mahogany
Walnut
Pine
Solid. Expensive. Heavy. Would love to see this sanded and given a dark stain.
Walnut, finished with a light sanding and a thin Minwax coat for minimal protection.
Light. Inexpensive. Dull. Could be covered with a light natural stain coat.
BO DY MI RROR
CMF / HIGH
BAS E
PL A ST I C B O DY Plexiglass
HDPE
Polypropylene
Common, but too see thru.
Great all around material with a clean white finish. No paint needed.
Does not have the smooth finish I am looking for.
MI R R O R Black Chrome
Too dark, although captivating, looks like a screen.
Polished Aluminum
Translucent Plastic
Shiny with mirror surface, yet not overwhelming.
Not reflective enough.
PL A ST I C B A SE Dark Reflective
Light Grey Frost
Heavy Frost
Way too dark. Couldn’t see anything.
I chose this because it gives the screen a little more presence than if it were clear.
Too frosted, couldn’t see through it.
FIN AL DESIGNS
LOW VOLUME
HIGH VOLUME
LO W VO LUME / E XPE NS I VE
H IGH VO LUM E / I NE XPE NS I VE
M ARC I $ 25K
M ARC II $2K
T H ANK YOU
Special thanks to Ron Boeder for teaching the course and to my father Gaston Marchand for the love and support.