c# create barcode Figure 12 9. Two-piece parts prototyped using FDM process in Objective-C

Creator Denso QR Bar Code in Objective-C Figure 12 9. Two-piece parts prototyped using FDM process

Figure 12 9. Two-piece parts prototyped using FDM process
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These boxes were created as two pieces a top and a bottom. As such, each part has to be prototyped meaning the cost doubles. In some situations, your mechanical designer could create a one-piece clamshell design where the bottom is more of a flap that is hinged to the top. I tried going this route, but it just didn t work for my accessory. I suspect there are very few cases where it would be successful. For FDM prototypes, the necessity to create two pieces for a single part isn t too big a deal. Some fab houses will cut you a break on your parts, especially if they see more business from you in the future. After all, an FDM prototype is a kind of a push the button
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CHAPTER 12: Everything Else
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and let it go manufacturing process. Once the machine is set up and initiated, the operator can walk away and the machine runs until it is finished. For a machined part, the process is much more operator intensive. While the machining is still automated, an operator pays closer attention to the process to make sure things go smoothly. As a real-world example, each set of parts (top and bottom) in Figure 12 9 cost me $77 to create using the FDM process and took a day to get done. In the beginning of this section, I said that you had a couple options on mechanical design. I will get to the second option soon, but let me say a couple more things about your first option. So far, you ve spent maybe a thousand dollars on a designer to create a model of your enclosure. You ve also had some prototypes made using FDM costing you a couple hundred dollars so let s say you ve spent about $1200 so far. Remember these are prototypes, not the final product. So how does the final product get made and how much does it cost The good news is that the final parts might cost you something like a buck apiece. It ll depend on quantity and complexity of the part of course, but it ll probably never be more than two or three dollars at most per part. You can probably live with that. The parts are made by creating a mold based on the mechanical model. The mold is typically a hard or soft steel. The harder the mold, the more parts it can be used to make. A hard steel mold is typically guaranteed to make 500,000 to a million pieces. A soft-tooled mold might make a couple hundred thousand pieces. Now, the bad news; a mold will cost from five to fifteen thousand dollars to make. The more complex the mold, well, you can guess which end of the price spectrum that ll approach. In fact, should you design to create an accessory requiring custom shaped, molded parts, expect the mechanical part costs to far outweigh any electrical design costs. Think about that for a moment. You probably thought that all those tools and test equipment costs were going to put you out of the game; then I throw in something that costs $10K. You re probably thinking that because your box is two pieces, that means $20K not just ten. Not necessarily. Molds are made up of cavities. A cavity is the area of a mold where the part is created. A mold can have several cavities. Two, four, and eight cavity molds are common. Of course, more cavities increase the cost. For the box design in Figure 12 9, my fab company created a two-cavity mold. The top part was in one cavity, the bottom in the other. While this didn t double the cost of the mold, it did increase the cost because the mold was now more complex. In general, expect a two-cavity mold that contains the two halves of your enclosure part to add about 50% to the single cavity cost. These numbers are only examples of course. You ll need to discuss it with your design engineer and local fab houses to get your exact costs. Still, it s going to likely be the most significant cost of your entire project. One thing you can do is to create your prototypes using machined parts to get that professional look, then go out and sell your accessory. I don t mean to actually take
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