Pete Goolsby
04-20-2005, 07:31 AM
We need to package 3 electronics PCB's, one RF diplexor, about 8 cables and a connector bulkhead into something kind of sexy we discovered in the gallery at Rhino 3D. Here's the problem:
This RF/computing platform device consumes ~30watts and fits into a 1 square foot, 2 inch tall volume, and because we are all EE's with one junior ME we are about to throw in the towel on electronics packaging because we all believe that it takes a minimum of 12 weeks to get quality tooling before first shots. We also believe that we need to pay $75,000 - $100,000 for tooling fees and spend more $$$ and times debugging the mold and material processes. With a projected lifetime run of ~500 units, the per unit cost of conventional molding is too high, so instead we are going to go back to a pizza box type design milled out of a 3" thick aluminum blank and get on with life. So much for a sexy product, but hey, we are in the utlility business, not the consumer sector, so sex is not very common in this industry. So, the safe, comfortable, risk-free trajectory seems the easiest, lowest cost path. I figure it is going to cost about $350US per chassis in material to hog out each part from aluminum blanks. Lucky we are located across the street from an aluminum foundry!
We did find a material from www.coolpolymers.com that was half the cost of aluminum, conducted heat as well as we required for the 30 watt application and volume footprint. But somehow we think the above costs and timelines apply because all we know about is injection molding electronics cases out of ABS and similar materials for radios that are either in a handheld
or utility pole form factor. This application resides in a vehicle and is not requried to be weatherproof like the rest of our product line.
<_<
Ok, so I knew about SLA's and even used it to prototype a one off weirdo digital camera for marketing where I used to work. The last time I looked at SLA technology was in 1999.
WHOA!
LOOKS LIKE RP HAS COME ALONG A WEE BIT IN THE LAST 5 YEARS!
:blink:
I write to discover if RP can:
A] Help us get a nurbed type product design mold created that will last for about 500 cycles that can produce aluminum or coolpolymer electronics chassis for a 'reasonable' price and within 30-45 days.
B]Produce someone, some company, or some consultant that can serve as a design liason to myself and my junior M.E. to take us through the RP process and technique selection process so we can learn to feed ourselves next time.. If you are a proprietor or RP advocate I am more likely to work with you than a consultant or sales jock. So there. You might need my free expertise someday to. Whatever happened to the "I owe you one" mentality?
C] Connect us to the 'unknown' shops in the RP industry that have fair prices, quality processes, products and machinery and are honest and forthright to industrial RP virgins such as ourselves ... and promise not to take advantage of us because if we find out we'll never talk to you again...
If you have read this far and are interested, ring me up. Maybe we both can learn a thing or two.
I've explained my motivations and you will need to explain yours if you call. I answer all email.
Thanks for your time.
Pete Goolsby
509-954-9566
pete.goolsby@itron.com
Engineering Project Lead/Product Development Manager
RF Hardware Engineering
;)
This RF/computing platform device consumes ~30watts and fits into a 1 square foot, 2 inch tall volume, and because we are all EE's with one junior ME we are about to throw in the towel on electronics packaging because we all believe that it takes a minimum of 12 weeks to get quality tooling before first shots. We also believe that we need to pay $75,000 - $100,000 for tooling fees and spend more $$$ and times debugging the mold and material processes. With a projected lifetime run of ~500 units, the per unit cost of conventional molding is too high, so instead we are going to go back to a pizza box type design milled out of a 3" thick aluminum blank and get on with life. So much for a sexy product, but hey, we are in the utlility business, not the consumer sector, so sex is not very common in this industry. So, the safe, comfortable, risk-free trajectory seems the easiest, lowest cost path. I figure it is going to cost about $350US per chassis in material to hog out each part from aluminum blanks. Lucky we are located across the street from an aluminum foundry!
We did find a material from www.coolpolymers.com that was half the cost of aluminum, conducted heat as well as we required for the 30 watt application and volume footprint. But somehow we think the above costs and timelines apply because all we know about is injection molding electronics cases out of ABS and similar materials for radios that are either in a handheld
or utility pole form factor. This application resides in a vehicle and is not requried to be weatherproof like the rest of our product line.
<_<
Ok, so I knew about SLA's and even used it to prototype a one off weirdo digital camera for marketing where I used to work. The last time I looked at SLA technology was in 1999.
WHOA!
LOOKS LIKE RP HAS COME ALONG A WEE BIT IN THE LAST 5 YEARS!
:blink:
I write to discover if RP can:
A] Help us get a nurbed type product design mold created that will last for about 500 cycles that can produce aluminum or coolpolymer electronics chassis for a 'reasonable' price and within 30-45 days.
B]Produce someone, some company, or some consultant that can serve as a design liason to myself and my junior M.E. to take us through the RP process and technique selection process so we can learn to feed ourselves next time.. If you are a proprietor or RP advocate I am more likely to work with you than a consultant or sales jock. So there. You might need my free expertise someday to. Whatever happened to the "I owe you one" mentality?
C] Connect us to the 'unknown' shops in the RP industry that have fair prices, quality processes, products and machinery and are honest and forthright to industrial RP virgins such as ourselves ... and promise not to take advantage of us because if we find out we'll never talk to you again...
If you have read this far and are interested, ring me up. Maybe we both can learn a thing or two.
I've explained my motivations and you will need to explain yours if you call. I answer all email.
Thanks for your time.
Pete Goolsby
509-954-9566
pete.goolsby@itron.com
Engineering Project Lead/Product Development Manager
RF Hardware Engineering
;)