Getting pretty close to production. Currently converting the mock ups to code. Updating the electronics designs. I need to order a Cricut to make the box design and start the factory.
Our designer created a stunning layout that will be included in the v2 launch.
The electronics was a really hard problem to solve. Mainly it was using the esp8266 which didn’t have firmware protection. So it was updated to use the esp32. A benefit with the esp32 is that it also has bluetooth. The current drawback with the esp32 ble is power consumption is ~10x what other ble modules consume.
Looking at the breadboard now, it looks much simpler after so many revisions.
Here’s a prototype with the esp8266.
The bme280 sensor was also replaced with a better one. We were getting a number of complaints from sensors being less accurate with time. It was actually cheaper to use the other sensor since it was meant for harsh environments rather than updating the enclosure design to further protect the sensor.
Once these pieces are complete, we get to start production. Production looks fun because v2 was spent on developing a scalable product. Whereas in v1, the fun part was developing features and then seeing it work.
The most exciting thing about production is my manufacturing thesis. In v1 there were two lessons I learned.
One was the viability of using desktop 3d printing for low volume production. We were outsourcing through a printing farm. In 2017 when prototyping v1, FDM 3d printing still had a lot of layer lines so it didn’t look polished. But by 2018 it was and it’s getting better.
The second was automation. I did a technical write up on this last year.
What is fascinating is how disruptive these two technologies are. With the Festo project I was using OPCUA to control a PLC controller. Automation is mainly using PLC, but any over the air stuff is usually federated and locked down (proprietary software) by the vendor of the machine. This means there is a bottleneck between machines from different vendors if you want them to talk to each other. The other is the RepRap project and how it can be extended to automation.
This is a 3d printed robotic arm project from Thingiverse.
Our robotic arm that assembles our device is 3d printed. And our 3d printer was printed by another 3d printer.
I say 5–10 years away where it’s mainstream that 3d printers print stuff to manufacture things. It costs at least $5000 for a robotic arm for manufacturing. It costs $500 for a 3d printed robotic arm. There will need to be more designs and iterations and more open source software to control it. Software wise, it will all still be plc. A lot of these projects are using a ROS.
