Project update #11
Hi everyone,
Here’s an update from the past two weeks.
We’ve been focusing on a few key areas of development, along with some smaller adjustments and changes. Below are the main highlights of our progress:
Prototyping Investments
To enhance our prototyping speed, we’ve made a few key investments. These include expanding our printer fleet with new additions and acquiring milling attachments. These improvements not only accelerate the production of metal prototypes but also allow us to test final production methods directly on our prototypes.
Tension Arm Redesign
We’ve made several updates to the tension arm design, particularly the upper wire guide, for a variety of reasons:
Improved Wire Rewinding: By increasing the distance between the wire guide and the spool, the wire now spools much more neatly, reducing tangles and inconsistencies.
Reduced Heat Buildup: The section of the wire between the guide and the workpiece tends to heat up the most during operation. Shortening this length reduces heat buildup, lowering the chances of the wire snapping.
Standardized Components: Adjusting the tolerances for certain holes allows us to use standardized parts for the wire guide. This change not only lowers production costs but also simplifies repairs and enables us to include spare parts more easily.
Enhanced Conductivity: With the switch to stainless steel, the entire tension arm can now act as a conductor, allowing both the top and bottom sections to supply voltage. This change decreases the resistance in the wire and further reduces heat buildup.
Removing allignment pins:This simplifies the assembly process by reducing the complexity and the tight tolerances previously required in this area. Alignment is now achieved by the components being sandwiched between the sheet metal parts, maintaining precision while streamlining production.
Tension arm testing
One reason for the delay in releasing this update was the wait for our stainless steel parts to arrive. To speed up the prototyping process, we opted not to powder coat these prototypes. Although we haven’t had the chance to conduct an in-depth testing campaign yet, initial tests show promising results. The deflection is nearly negligible, and the wire can now handle higher currents. We’ll share more detailed insights into the prototype’s performance in the next update.
Safety
We’ve implemented several safety improvements, focusing on both the user and the environment in which the machine operates. These changes, though relatively small, are essential for ensuring a safer experience.
For example, we lowered the water level in the machine by about a centimeter to reduce the risk of spills. Additionally, we upgraded our AC-DC converter to one with a higher safety rating. While these adjustments don’t affect the machine’s overall functionality, they required time for careful implementation and testing.
What's next?
We have several prototypes in the pipeline. If the new tension arm prototype performs as expected, our focus will shift to the electronics. This is a critical area since we rely on suppliers to manufacture our PCBs. Here are the key areas we aim to improve:
Improved Heat Dissipation: Optimizing the design to handle heat more effectively.
Standardized Components: Replacing certain components with more standardized options to reduce lead times and enhance scalability.
Enhanced EMI Resistance: Addressing electromagnetic interference generated by the spark by improving PCB shielding.
Another significant focus area is the outer shell of the machine. This involves refining the fabrication techniques used in its production. The current process for producing the outer shell is time-intensive, and we see opportunities to streamline this by redesigning fixtures and mounting points.
Reliability is, of course, a constant priority. We’ve ordered several components to enhance the machine’s dependability. Some improvements are straightforward, such as replacing the winding motor's plastic gears with metal ones for greater durability. Other changes are more substantial, like identifying a new supplier to ensure higher-quality and longer-lasting parts.
We'll keep you updated.