I went to my old job and took apart their new 3D printer

0:00 about a year ago formlabs called me up and asked me

0:02 if I wanted to beta test this machine it's a form four

0:05 and I was very interested because I used to work at formlabs

0:07 I worked on the form one the form two the form three

0:10 but not the form four so I said yes I want

0:12 to try this machine and see how good it is and I

0:14 actually used it a ton I printed all the parts for the dis

0:17 launcher on it total Workhorse I actually went and bought one

0:20 once I needed to return the beta cuz I wanted to keep

0:22 using it and then a few months later when I was

0:25 up at the office they asked me if I wanted to tear

0:28 one down and I said yes so they gave me a brand

0:31 new printer a screwdriver and the engineering lead for the project Alec

0:36 Rudd and he answered all my questions which were many I actually

0:40 went so long that the batteries died on our microphones so apologies

0:44 in advance the audio quality drops towards the end because we had

0:47 to switch to a fallback mic so if you're wondering why

0:49 there's an hour plus video that's like 4 hours of me taking

0:53 a machine apart compressed down into the smallest nugget possible so here

0:57 we go okay so this is a form 4 uh it's a prettyy

1:01 good printer I've been printing on it for 3 months I

1:05 haven't had any failures and I've been really curious to see inside

1:09 of it this is Alec Rudd he was was and is

1:12 the tech lead for form four and so what we're going to do

1:16 should be really interesting we're going to take this thing apart

1:18 and I'm going to ask him how everything works and we can

1:21 get a really neat internal dive into the machine and I have

1:25 no idea what what I'm going to see so and I'm going

1:29 to do things that that make you uncomfortable this machine so we've

1:33 got an assortment of tools how many hours did you spend developing

1:37 this 2 and 1 half years times 10 hours a day five

1:42 days a week I'm not going to do that math on the right

1:45 let's see how long it takes to take tear it apart

1:48 to break my spirit uh so we'll start with the back is

1:56 this something a user would ever have to do uh yeah all

1:59 of our main replaceable parts are accessible through or most remain replaceable

2:03 parts are accessible through the back panel do this yeah so

2:06 you can take off that panel and they'll be able to replace

2:08 the cartridge floor the dispense assembly uh the level sense and the camera

2:14 is this for like what is the little port hole for yeah

2:19 so you can um we're going to have a a 3D

2:22 printed adapter for hooking up to a ventilation system so they have

2:26 the small little um lab scale ventilation systems you can hook up

2:29 to I saw that on mine and I thought like that connector

2:33 must really stink you have to be able to get to it

2:36 to fix it or something there's like is that a dash

2:39 pot yep yeah yeah can you guys see this thing in here

2:42 when this comes down that little looks like a little shock absorber

2:46 is that really necessary it's nice no Slammy no slamming yeah

2:55 that's nice what do they is there something that those are used

2:59 in normally like why are they so affordable like VCRs or something

3:04 uh they're probably I'm actually not sure what the main industry is

3:07 but they're like readily available on most industrial websites be like like

3:11 um drawers for like soft drawers they have like more specialized ones

3:16 but it's a pretty similar so that's from drawers that makes sense

3:21 there we go okay sorry so so this is this is probably

3:30 the hardest injection molded part this is the by far the hardest

3:34 injection molded part this is crazy it's a lot of square

3:38 parallel faces all Cosmetics two parts right so there's a a well

3:45 or a glue joint here yeah a little glue joint there that's

3:48 jigged at the factory and glued how long did someone spend trying

3:51 to get this friction hinge everything working nice oh and these are

3:57 clutched yeah those are there's a one way for H yeah so

4:00 it's not really clutch but it's really hard to push the other

4:03 direction yeah you can't but they spin freely that way what's

4:08 the mechanism is it do you know what's inside there I haven't

4:10 taken one apart I'm not entirely sure what the what the mechanism

4:12 is like it's like a roller cam thing or something yeah it

4:15 doesn't seem it's like a hinge how much work could it take

4:18 to make a hinge but I bet someone spent like months just

4:22 getting the right hinge testing the slamming they probably slam the cover

4:26 10,000 times to make sure it doesn't break that it doesn't wear

4:29 out that it feels premium and it doesn't cost a lot

4:31 of money and what's the purpose of this that helps uh guide

4:37 the cartridge when you install it so you don't get it

4:39 to jam up on anything it's just kind of like a pokeo feature

4:44 so when the cartridge goes in you can catch it here yep

4:49 so this is like a funnel yep to feed the cartridge down

4:53 and it prevents you from inserting the cartridge uh backwards as well

4:59 people will people will try people are really good at finding ways

5:04 to get the machine to do things that you never even

5:06 thought on the form one you could put the tank in reversed

5:10 which no one ever tried ever and you could also put

5:12 the build platform on upside down which that's a fun one and then

5:16 slam the cover on break the cover I don't know if anyone

5:19 broke the cover but you could and then this is all new

5:22 so this is this is the cartridge all the resin pours out

5:26 of this and it's really hard to make these cuz they make

5:29 a million of them they can't leak when you're shipping they

5:32 get squished and stepped on and pressure changes but ultimately it's pretty

5:36 simple so there's a bite valve or a rubber valve that you

5:40 squeeze that lets liquid out like a bite valve on a back

5:45 but this isn't stock this is yeah yeah so we developed

5:48 our own bite valve um a lot of our resins are pretty high

5:50 viscosity so the stock bite valves you can buy uh don't Flo

5:53 the resin out fast enough so we wanted to have a faster

5:56 filling tank and be able to keep up with the print

5:58 rate of the machine and then and then also like there's all

6:01 this extra geometry is that for drips and yeah for drips

6:05 and just to kind of help it all return back to it uh

6:08 shape and seal itself I mean it's it's crazy like we could

6:11 probably talk about every part in here and people have talked about

6:14 every part in here for weeks to get it to get it

6:18 right and understand all the detail and then how does it know

6:21 when I put this in how does it know what the material

6:23 is yep so there's an RFID tag hidden under uh the sticker

6:27 you can see the outline of it yeah you can rip it

6:28 off oh y there it is so this is what the cartridge

6:35 sits on so what are we seeing here this is a scale

6:39 little mini scale so if I slam it do I bend

6:44 the Lo cell no so there's a a flexure on there

6:48 that helps protect the load cell and keep it safe and then there's

6:52 oh I'm going punch the the thing you don't expect about

6:56 these load cells if you just hit them they Bend and it

6:58 now says a c weighs -2 kg or something like that just

7:02 even in this little cell there's a safety mechanism that will if

7:06 you overload it it will bend down and then hit a hard

7:09 stop so you don't break the load cell what are they not

7:13 Toyama the little Japanese motors is that what you're using for the bite

7:18 valve yeah it's a little uh DC geared motor see if

7:21 we can get it out don't tell me I won't this guy

7:25 out of here so like something like this cartridge bike valve

7:30 in the little motor that actuates it how many people worked

7:32 on that how long did just that take yeah so we had like

7:36 probably two main Engineers working on that um we had somebody

7:40 that was responsible for making sure that the cartridge was going to do

7:43 everything it needed to do and design the bite valve and we

7:45 had another person designing all

7:47 the mechanisms and printer integration the cartridge

7:49 itself and the bite valve was a good like few months

7:52 of of development to try to get everything right we probably went

7:54 through pretty fast H yeah it's probably more than I'm not

7:58 from trying to call you out yeah from start to finish it was

8:01 probably like 6 months for the bite valve and then we did

8:04 like more iterations after we thought we were done yeah I mean

8:07 you sent me a new cartridge floor on my Beta so like

8:10 there's still still some still bugs you're working out and I'm probably

8:14 doing this wrong aren't I like I shouldn't do I should take

8:16 off this first maybe uh no you can take you can take

8:19 it off from there um am I supposed to get you can

8:21 take it off well do you want me to tell you no

8:24 okay oh that's is this just a shroud no that's actually carrying

8:29 the camera is this like the standard Raspberry Pi camera cable yeah

8:33 that's a mippy cable nice yeah this is a really cool you

8:36 can actually see the the protection so I worked on the form

8:42 3 how many parts from the form 3 if any are

8:46 being used in this machine uh directly almost none probably zero oh

8:53 no we're using the leveling feet are the same ah so

8:55 we got one those aren they those are off the shelf are

8:58 they they're hexagonal I think we make those there's custom yeah

9:01 which I think is the same as the form 2 feet so

9:04 this is the crazy flexal mechanism does it bottom out on here

9:09 uh so it bottoms out on this nut so it bottoms out

9:12 on the other side actually because the this whole thing is

9:15 going to be deflecting mostly vertically so it'll short all the force

9:19 to that n it's flexing around yeah like almost flexes forward and then

9:23 kind of un way yeah so that nut is exactly the right

9:27 I guess you designed it just to use a yep a standard

9:30 nut that's why we have like custom spacers and stuff to get

9:32 everything I see so load cell sits here if I body slam

9:37 the cartridge down it'll this metal flexor will Bend forward and hit

9:42 that nut and it'll keep us from deforming this aluminum I

9:46 assume this is aluminum looks like aluminum if you don't have

9:49 this this is like Pro tip for other product Engineers it's not

9:53 going to work very well in the field let's get this off is

9:57 there any issues with like thermals were always a big problem

10:02 on machines andan it makes load cells drift it makes there stuff

10:07 that changes when you take it to like ice cold place or hot

10:12 place was that an issue at all um it's not a big

10:14 issue there is a little bit of load sell drift not

10:16 enough to to Really Matter for what we're trying to measure about

10:19 with yeah so we have uh temperature sensors in the tank measuring

10:23 resin temperatur so we're able to compensate for you know any cold

10:25 environment we test down to 18c I think so that's pretty that's

10:29 like what 55 fahrenheit I something like that yeah it's like it's

10:32 pretty cold unheated garage unheated garage yeah I saw this on mine

10:36 I I actually had no idea what this was for but I

10:39 someone told me some guy designed some somebody designed little guitar

10:45 pick special shims for build platform this is this is build platform

10:49 leveling yep that's build platform leveling is it also LCD swap

10:53 or yeah after you swap an LCD you want to kind of relevel

10:56 the build platform the Allen R for LCD swap and you can

10:59 also take out the back panel with those Allen wrenches so you

11:02 can do I think every major service loop with just the tools

11:04 that so these two Allen keys and then the guitar picks yep

11:09 does it guide you through on the user interface yeah yeah

11:12 for BP parallelism it's a fully guided guided operation is there anything

11:17 else to rip out before we go to the front rip

11:20 out Sanic and C let's pull out Sanic Sanic is code name

11:25 for an ultrasonic level sense system another big problem with these machines

11:31 is that you have to know when to stop pouring resin out

11:34 of the cartridge you can't just turn it on and hope

11:37 for the best so this board should be the thing that tells us how

11:41 much resin is in the tank so it's ultrasonic what's the resolution

11:47 yeah for like a stationary Target we can get like quarter millimeter

11:50 usually wow it's actually pretty high resolution um it's a lot harder

11:53 with the resin cuz it's like moving around and splashing and doing

11:55 all sorts of stuff well with that mixer it's like never it's

11:58 never really least level are you using AI to tell you how

12:03 unfortunately actually unfortunately no we're not using AI is there any AI

12:07 in this machine there's no AI in this machine to my knowledge

12:11 yet do you watch the news is going to take over

12:15 and and get us with the camera there's definitely AI potential yeah

12:21 what's your favorite part of this machine uh I think the LCC

12:25 module is the coolest has like the most technology packed into one

12:28 single component so that's what we should get to yeah we

12:30 should get to that that's pretty fun to look at I want

12:32 to see that so this is RFID so this is how you

12:36 sense the tank yep that's for the tank okay so this is

12:39 a little ultrasonic transducer sends out a pulse and then listens

12:43 for it yep is it all custom it's all custom yeah yeah yeah

12:48 this is a form La board and that's how you're able

12:50 to get quar millimeter steady state or you say 500 microns or uh

12:55 yeah a quarter millimeter if we're just looking at a flat

12:57 plane and then a lot worse than that like the millimeter is

13:00 when we're doing uh moving resin I mean just this little thing

13:05 I could see someone that could be their job for a long

13:09 time and then we have a camera that's Torx in there

13:14 is there a reason this is Torx instead of hex everything that's

13:17 user replaceable is an allen wrench so something that you shouldn't take

13:20 off is Torx something you shouldn't take off is Torx yeah is

13:23 there any Security torqus on here we have no security torqus yeah

13:27 that was a little uh extreme for us well there might be

13:30 some like do not loosen this or it will like you'll have

13:34 to send it back on the on the other machines there was

13:36 stuff if you loosened it you're you're done that was it

13:39 yeah is there anything on this machine if I loosen it like

13:42 it's over no no pretty much every component is user replaceable I'm

13:46 kind of expect it to be user replaced so you can take

13:48 it apart we'll make you put it back together after this I'll

13:51 never put it back together yeah so this looks like a Raspberry

13:54 Pi camera uh yeah but then this is all kind C

13:59 is this custom or is this just a custom mount for it

14:02 yeah this a for custom board yeah we have LEDs and stuff

14:05 on there as well where are the LEDs are they right

14:09 there oh there they are so how long did it take

14:11 to get this angle of the camera that was a lot of work

14:16 I mean it's like not Square on any axis Twisted yeah

14:20 that was a lot of uh mounting cameras on flexible arms and like

14:23 repositioning and taking photos and repositioning

14:25 and taking photos and then looking

14:27 in CAD and trying to have like angle cones so we try

14:29 to figure out what it's actually seeing are the cameras consistent

14:32 the modules like do they always point the same direction or is

14:35 there any variability there's slight variability but you can always we always

14:38 have everything in frame okay so you can do you CR do

14:41 you calibrate that or is it just we don't do any calibration

14:43 for that right now we we just check to make sure everything's

14:45 in Focus that's a thing you actually check at the factory is

14:48 does the camera focus and have everything in frame Yep this is

14:53 a crazy little injection molded part that's cool let's see pull it

14:59 off oh yeah Raspberry Pi so this is like Raspberry Pi heart

15:06 yeah it's such a good ecosystem that's like so mature all right

15:09 where should we go next the front May yeah maybe the front

15:13 B so this BP oh is really cool so there's something like

15:21 this on form 3 but you had to redesign it again so

15:26 what kind of magnets is this Rare Earth um so there's

15:31 a hall boach array so this is a okay it's fine very good

15:42 so there's a hallo array Hall array sheet magnet under here

15:46 and then there are um neodymium magnets under the what we call

15:49 the troughs and that hold on to the this is all sticky

15:53 and that holds on to the the rods and keeps that from uh

15:56 popping off as you just just demonstrated yeah so this is

15:59 a magnetic stainless yeah it's a magnetic stainless yeah okay yeah

16:03 this is aluminum or no this this is the same stain t

16:06 spot weld it's all laser welded laser welded nice and these are

16:11 only laser welded right there well I think it's it's one

16:14 on the other side too isn't it uh in that little oh

16:17 it's laser welded the rod okay okay I no no it's not

16:20 just that one tiny face yeah how how much like this seems

16:24 like another really hard to tune thing like how many versions

16:29 of this did it take to get the like the magnetic like I

16:33 presumably you ripped these off from too much force and you had

16:37 to make the magnets stronger and stuff like that yeah I mean

16:40 luckily the form 3 design was pretty mature and we were

16:42 able to copy almost everything directly from the form three we just

16:45 kind like repackaged it and made it fit um form four yeah

16:49 I mean I was involved in that and it was painful I

16:51 remember that's why I'm asking doing that work for us I didn't

16:54 do it I was just I was there I remember the nashing

16:57 of teeth it's painful but good there we go there it

17:03 is that's cool it's very heavy what is that the hallac array

17:06 that like why is it so feel that is that normal

17:10 yeah that's normal CU it still has an aluminum Extrusion and like

17:14 a couple magnets and some steel it must be the hakay yeah

17:19 that is a very useful thing did you guys design the sound too

17:26 very careful Sound Engineering yeah yeah did you get the thickness

17:29 to get the right tone there was a lot of thickness tuning

17:31 of that to make it uh so it doesn't warp and bend

17:35 so this is another one of the deceptively challenging parts to get right

17:42 so this is the what do do you still call it

17:43 the dovetail uh yeah yeah we call it the dovetail the Z

17:46 stage and the dovetail and so it locks the build platform down

17:53 and it it has to be square and stiff and like very

17:59 difficult to make and also if you close the cover

18:02 on this you don't want it to punch a hole in the cover

18:05 right y so this is one and you totally redesign it

18:08 for this machine it looks like yeah ground up yep and it it

18:12 looks adjustable what is everything that this does there's what's all

18:16 the what's all the stuff in there yeah so we have um

18:19 a a build platform detection switch so there's actually an optical gate

18:24 uh deep in there that you can't really see deep in there

18:27 you have a flashlight you can probably yep so there's a little

18:31 so you push that in breaks the beam oh this is

18:35 the other direct form three part I think okay um yeah push

18:40 that in it breaks the beam it tells you that your build Platforms

18:43 in place um but it only it can only do that up

18:47 top so if I pull out the build platform really fast while

18:50 it's coming down yeah then you just that's your fault can't

18:54 the cover is interlocks yeah you could open the cover take the build

18:57 platform off and we wouldn't be able to detect that did

19:01 was this a uh was that tuned is this a that was

19:07 that was tuned yeah we tried to make that feel as nice

19:09 as possible and it's it's actually there's a lot more satisfying I

19:13 thought was going to going to be throughout development um that thats

19:19 was supposed to happen so this is just a little injection

19:23 molded piece a little diecast piece and so it shouldn't no it

19:31 still does it so that's just this piece flexing and snapping over

19:35 that little diecast piece yep and then what is this an over

19:40 molded yeah yes this is all like an over molded um Steel

19:45 part because that's going to be under constant um deflection so a plastic

19:49 one would have crept and would have uh changed its position too

19:52 much so there's a big injection molding tool someone puts a piece

19:55 of Steel in and they inject both these at the same

19:59 time or is it two steps yeah same time same time

20:02 and then you have a piece of metal inomed and there's a bunch

20:06 of details like there's a little hole is that what keeps

20:09 this does it go through the steel to lock this on the end

20:14 the steel has a little bit of like a t-shape to it

20:17 okay so it kind of like wraps around that t-shape so it

20:19 can't pull itself off what's this little hole I'm actually not sure

20:23 what that little hole is I see two ejectors but the hole

20:27 that might actually be the support for the that's that's what

20:31 holds the metal there's a there's a pin that goes in there

20:34 that's right yeah I see it yeah this is a cool part

20:39 is this is this all nylon uh yeah yeah this all uh

20:45 a glass B nylon cool gosh how long did this take

20:50 to to get designed and working this was like basically from the start

20:54 of the program up until we started going to NPI yeah we're

21:00 iterating on it constantly yeah um every time we Chang anything else

21:03 in the printer this had to change with it so part

21:06 of it was it getting tugged along with the rest of the design

21:08 but um there's a lot of tuning to get all

21:10 of these Heights just right make it so it's compatible with all

21:13 of our resins um getting the BP scrape uh functional there's

21:17 a lot of tune that goes into that yeah this looks expensive is

21:21 this all cnced this this whole thing on Extrusion do you

21:27 want to make it like I guess there's not really much value

21:29 to an extrusion is there you end up doing so much yeah

21:32 Machining after Extrusion that's all but this is like the heart I mean

21:37 this is critical this is a really important you didn't make it

21:40 expensive for bling Factor you made it expensive because that's the only

21:44 way that you could find to make it and so so

21:48 this is all CNC machined and then it has is this heat Stak

21:52 this yeah so that's a polypropylene um injection molded flexure that's heat

21:56 staked on at the factory that's cool and then there's a hole

22:03 hold on hold on this way so you've got yeah it's

22:11 like that's nice is there a reason not to have it forever

22:17 attached um initially we're like oh it would be nice if you

22:19 can clean this stuff separately uh but we actually going to change

22:22 it to be forever attached okay I dropped yeah I took

22:25 it out and like or actually I was trying to like do

22:28 do something in the tank and I it came off and it's

22:30 like really hard if you don't know how to yeah so

22:32 we're going to fix I also put it on backwards or no

22:35 how did I do it I think I went through I told

22:38 you users find really dumb things to do I think I

22:40 put it on upside down like this and tried to slam it

22:44 in and it it went in but it was sitting like this like

22:48 that doesn't seem right not right yeah it would have detected it

22:52 with the smarts so this you I I got distracted so

22:57 this this also does leveling yes right this also does leveling and then

23:01 and then there's this there's a whole mechanism on here which which

23:07 should we get that off I guess we should get that off

23:09 so we can look at it then we'll get to the lpu

23:13 if we have time I'm going too long but there's so

23:16 many parts no that's that's and this whole thing here looks diecast

23:28 is it diecast yep yeah yeah this base part diecast and then

23:30 this is extruded okay well I be able to get it

23:36 off with the um oh yeah we there's a lot of pieces

23:46 in this what's the I guess we'll have to get that on camera

23:49 but what's the uh purpose of this little the little spring does

23:59 that hold two sides of the spring does the other side go

24:01 in there yep uh yeah so it's like a little carabin spring

24:05 oh that's cool it's like little did you just like take

24:08 that from the caraban or was that the inspiration that was the inspiration

24:10 from for that spring yeah that's really clever I don't we

24:14 didn't yeah we didn't do that before and there's do these also

24:20 push out or is it just the one side no now

24:24 le are screwed in is that a datm uh the datums are

24:28 the bottom here and then that's that's really it we don't do

24:32 very precise control in Theta Z it doesn't really matter see if

24:37 I can get this out of here okay there we go got

24:40 it that's that's in the printer now but we're going to get

24:43 in there and take it it out wow so this is

24:49 the does it have to be that that beefy that beefy I mean

24:55 that is crazy yes we want to keep everything as stiff

24:57 as possible so when we're printing with really viscous resins you don't get

25:01 the whole thing kind of clam shelling open um and this was

25:05 one of the big areas where you you have a big moment

25:08 on that part what about the tower oh you have a huge

25:11 rail nice yeah we went to the flat rails from the form

25:15 3 which just a big old yeah is that the same one

25:18 that's on the 3L or is that uh it's not the same

25:21 as the 3L it's similar yeah all right so here's your little

25:25 flag for b-roll purposes what what does this do oh that's

25:33 the end stop yeah okay so there's an optical sensor that detects

25:36 this to home and there's an optical sensor detects this now there's

25:39 a build platform in it this is a crazy diecast part give

25:45 your a cool Carabiner spring so what's actually moving to latch it

25:52 h a little draw bar there oh there's down here oh

25:58 oh that's cool so it's it's kind of like a milling machine

26:03 or something there's a draw bar that t- slots into this t-lot

26:10 groove with this little round thing and it pulls the build platform

26:15 up against the dovetail so it just locates it like that doesn't

26:21 really care too much about rotationally yep just planer okay it pulls

26:26 it with like there's a lot going on 500 Newtons or something

26:29 the preload on it like pretty high really high yeah and then

26:32 is that floating cuz like when it moves around okay so

26:37 that all moves with it I see so I was thinking if

26:41 if this moves and that's fixed to this then right you can

26:44 never get change exctly yeah so all moves together this that one

26:50 actually if you go look at our original Proto one in the other

26:52 room um it's very close to what this is right now

26:56 you just nailed it like we did it pretty well it took

26:59 us like a couple of tries and then it was small refinements

27:02 to get the packaging smaller wow um but yeah the team

27:05 that worked on this did a really good job of getting it uh

27:08 yeah and this is totally different than form three like this is

27:11 completely all new like we didn't use a draw bar or anything

27:16 that's cool all right now the good part lpu I guess

27:20 tank as well so this is one of the probably deceptively simple

27:26 it's one of the hard it looks simple but it's really hard

27:30 how long did this what looks like a piece of plastic take

27:34 uh we went through a lot of iterations on getting the steel

27:38 ring right getting um all the heat sticking right um we're

27:42 holding the film under a lot of tension so we have

27:44 to be able to pull that tension and not have this whole thing

27:47 like buckle and War like twist or something weird yeah yeah

27:51 so it took a lot of this was like probably a year

27:53 and a half to get to get this this right um and then

27:56 there's a whole production problem of doing that and then doing it

27:59 consistently every single time like are you measuring the like for every

28:03 tank do you measure how tight it is and everything yep

28:06 yeah did you have issues with creep I guess that's why you

28:08 have the metal rings that's why you have the metal rings like

28:10 the backbone of the whole thing yeah and did it so so

28:14 you like at the factory you have to tension this evenly yep

28:19 do you tension it with a circle or do you no we

28:22 we tension it with two two axes two axes yeah but we

28:25 were really worried about that and we were looking a lot

28:26 at doing like a big circular ring um but we test it

28:30 with two axes it seemed to work fine and we were able

28:32 to do tension Maps across the whole tank and make sure it's

28:35 even and kind of what we expect and so you just heat

28:38 stake it down is there any sealant or is it just squeezed

28:41 really hard squeeze really hard heat stake it down yeah this whole

28:44 thing is clamped in a giant press yeah while it's being heat

28:47 staked wow and there's is there presum there's like an edge

28:52 that is bent around or something yeah yeah there's like a cap stand

28:55 in there that the whole film is bent around to kind

28:56 of give it a good ceiling face and then you've got this is

29:00 for the mixer where what's the purpose of the cutouts um

29:04 it just reduces the stiffness of this oh okay yeah so it

29:07 can like preload against it yep yeah it sits flatter did you

29:12 have any issues with like ejecting resin with that super fast mixer

29:16 Yeah we actually spent a lot of time in the initial

29:18 tank design trying to make sure it wouldn't eject resin so we

29:20 we called that tsunami in or geering well first it was tsunami

29:24 then we added tsunami deflectors and then we realized that we were

29:26 shooting resin out of this little hole here so then that became

29:29 a geyser Old Faithful yeah Old Faithful this is yeah cuz

29:31 this is like a tsunami wall the whatever they have the wave

29:34 breaks on beaches so tries to redirect it back at itself yep yeah

29:39 you can like watch the resin in slow motion we did

29:41 a lot of slow motion footage when we were developing this you

29:43 could see the resin like hitting the wall coming up and splashing

29:47 back over and make sure all the resin stay in the tank

29:50 it's really hard to move the the wiper at you know

29:52 close to a meter a second like 750 mm a second back

29:56 and forth without spraying resin everywhere

29:58 and you're accelerating it really fast

30:00 too do you know many G's you're uh we're doing we're doing about

30:05 a g we're doing 10,000 millim a second doesn't sound like

30:07 a lot but a G is a g is a ton yeah

30:11 that's like I mean that's pretty fast G yeah I think

30:16 this tool has like the most actions of any tool I've ever seen

30:20 yeah because there's an action for every single one of these yep

30:23 so an action in the tool is like a moving part

30:26 that allows you to create a feature that you wouldn't normally be

30:29 able to do in an injection molding tool cuz it's undercut you guys

30:33 go through so many tanks in the Prototype that you actually make

30:36 an an injection molding tool just for testing that you know you're

30:39 going to throw away yep because otherwise you'd be spending hundreds

30:44 of thousands of dollars on machined or 3D printed or yeah and so

30:50 so you did that two or three times and then you

30:53 made the final one made the final one yeah wow so yeah

30:57 basically every part in here there's like it's the it's the crazy

31:02 thing every single part in here there's someone who knows everything about

31:07 that part and if it changed at all they're going to like

31:10 get upset and care and try to fix it and and there's

31:14 a lot of parts so it's amazing the amount of work

31:17 that goes into these things what about these with these little clippy things

31:22 for the tank was that easy or hard uh that was also

31:25 pretty hard there's a lot of debate on how to do it

31:27 um we had a lot of Concepts that were like much more

31:30 complicated and had like one lever that clamped the tank in it

31:33 was like really really Sleek uh but we decided to go just

31:36 like Tupperware latches we called them just for uh reliability and robustness

31:40 um and it kind of just it's just a little snap

31:43 fit yep is there flexure in oh wait these are spring loaded

31:47 those are spring loaded what okay so you have a spring-loaded latch

31:53 on like a sheet metal carrier and that entire thing is springloaded

32:00 up so that sets the the force down on the tank

32:04 and if you didn't have that any variation in the tank it wouldn't

32:08 hold it snug and tight it might be too hard did

32:11 you try doing it without those Springs or we did some prototypes

32:14 about the springs and then yeah exactly what you said any variation

32:18 made it so the fu was bad or tanks would come loose

32:21 did did Max try to make you make it a flexure

32:25 in the injection molded part no fortunately he did want us to make

32:28 it a flexure in the chassis right now it's a separate

32:31 piece of Steel that comes up with springs or a it's just

32:35 a flexure oh that's a flexure I'm pulling on yep that's good

32:38 yeah just a metal flexure yeah it's GNA be hard to get

32:41 to that that's a maybe you can like show this won't

32:44 take it out here oh that's the side shell that's the side

32:46 yeah we like barely got into the machine let's do that yeah

32:49 all boring stuff let's do the lpu it's not boring but compared

32:52 to the lpu some some might say it's boring not me all

32:58 right so if I was a user and I dropped a dumbbell

33:02 on my LCD this is what I would be doing to replace

33:05 it these eight screws and there's a little what's that it's

33:14 this little a little thermoformed piece or something yeah it's a little

33:19 thermoformed piece it's a window it's a window for an IR sensor

33:23 oh okay like a thermopile yep so that's how you s

33:27 the resin temperature that's how we sense the resin yeah it looks up

33:30 through that little window and it hits on the tank right about

33:33 here yeah and it works on all colors of resins there's no

33:37 they're all absorbed yeah it's actually measuring the tank the tank

33:41 fill more than anything so it doesn't see through the tank doesn't

33:43 see through the tank yeah so this tank looks black to the IR

33:47 to your one pixel camera to our one pixel camera yeah

33:51 cool all right so there's eight screws and I guess before we

33:56 get into into the this uh the top of this looks crazy

34:02 is this glass what is what is this material yeah so that's

34:06 a actually a plastic material it's a basically a plastic micro lens

34:10 array that we made uh and it's hard coated with a special

34:13 coating that PR um prevents it from getting scratched um prevents

34:17 resin from sticking to it so you could actually cure resin right

34:19 on top of it and then just like peel it offel it

34:20 off uh which is pretty cool so a resin spill isn't catastrophic

34:24 like it is with a lot of machines when you get it

34:26 on there yep all right let's see if I can get

34:28 this out don't don't tell me how I've never read the instructions so

34:32 I mean my first instinct is just Yank on it so

34:35 that's what I'm going to do this hope this oh that not

34:43 so bad oh wait okay there's wire harnesses so there's a power

34:52 and then there this looks like a surfice Loop okay so just

34:55 a straight HDMI with like suspenders on it yep p suspenders

35:01 to make sure it doesn't get uh unplugged during shipping or uh so

35:05 it doesn't get damage as you're pulling it out is that a problem

35:08 you discovered the hard way or no that was a thing

35:11 that we uh were just worried about so we decided to just

35:14 kind of belt and suspenders it from the Geto okay and that's

35:18 actually a fused SLS part little SLS part little flexures that clip

35:22 on interface with the PCB this is one of those surprisingly

35:28 difficult to do things because you have to have your PCB

35:31 with exactly the right cutouts and then like your print Farm part all

35:36 matching up perfectly although this is easy to iterate on at least

35:39 yeah yeah okay so this is the LCD right and then we've

35:47 got heaters so this is just a circuit board with a long

35:51 trace on it yep long skinny Trace yeah and you just

35:55 pump electricity into it and it gets real hot yeah pretty much

35:58 pretty simple yeah uh connect positive negative why is there so many

36:04 conductors on them is that just a bunch of uh heaters

36:08 in paral or in parallel I guess yeah we also have if you

36:11 look there we have a little temperature sensor on each of them

36:14 whoa um okay so two lines are going to the temperature sensor

36:19 but that still leaves a lot of other yeah then the other

36:21 one is just um redundant for uh so there's a heater

36:25 on both sides presumably or is it just the one side uh

36:30 these are single sided yeah these are single sided these are aluminum

36:33 core single-sided okay um yeah these are the same board on both

36:36 sides okay and why is it soldered why isn't there a connector

36:40 uh it's just less expensive you just solder it directly there

36:43 yeah surprising you just hot bar solder so you kind just come

36:45 in and do all of them at once okay and then

36:48 this PCB is doing what it's just passives for the temperature sensing

36:53 and anything else do you know this is all the driver uh

36:57 uh for the the to power it yep okay yeah and this PCB

37:04 under it is um what's this surface here is this a datm

37:10 yep so this yeah so that registers onto the um printer frame

37:15 okay so that makes it always at the same height yep can

37:20 I over torque these oh those are datm to okay yeah was

37:23 that was there any problems with that like getting this no

37:26 so it's actually these are on little flexors in in there so

37:29 the frame itself has little um flexors so you can preload it

37:32 a set amount yeah which is a real that's the kind of thing

37:36 I would expect to really be like if you tried to just

37:38 screw all these down to something rigid it would probably like warp

37:41 it right if this ISAT out yeah well it could make

37:45 your LCD change like if you push on an LCD on an old

37:49 calculator it turns black right so yeah yeah you're get like some

37:52 funny streaks where it's not working and it's critical that this is

37:56 consistent isn't flat and not full of stress yeah no no

38:01 stress totally chill and you said this is a lens array is

38:08 this actually doing optical lensing we're trying to make it do

38:11 as little Optical lensing as possible while allowing as much air flow

38:13 as possible those two things are kind of at odds um so

38:17 there's a lot of work that was done it's definitely doing optical

38:19 lensing yeah you can see but it's less the closer you

38:21 get to it yep like I can see my hand just fine

38:25 not so bad pretty bad actually there we go there gets worse

38:30 my face is all messed up when that's that far away so

38:34 that looks like a really annoying part to to to prototype like

38:40 how do you how long did this take it took us we

38:45 went through I don't know how many dozens of of iterations

38:49 of trying to prototype this we had the idea we had the concept

38:52 we thought it would work um but we had no way

38:54 to actually test it so we spent as much time trying to figure

38:57 fig out how to do the first prototypes as we did like

38:59 making the getting the final design right it was months of just

39:04 how do I even make this half the time was yeah

39:06 how do we even like prototype it to prove out that it

39:08 can do what we want it to do um and that was

39:10 a big combination of like 3D printed Jigs and fixtures and uh

39:15 presses and stuff yeah and then once you're able to make

39:19 it you were saying it was then dozens of iterations to yeah

39:23 once once we could make it we did dozens of iterations inhouse

39:26 um because the the tooling to make a part like that's really

39:29 expensive it's really long lead time so we wanted to get it

39:31 right the first time so we did lots of varations inhouse so

39:34 we could make as many um do as much testing on it

39:37 as possible before we shipped and before we locked the tool design

39:41 down okay I don't think there's anything else to take off here

39:45 because it's all it's basically glued in right it's all that's all

39:48 poted in yeah what is this is this silicone that's silicone just

39:52 to seal it y okay yeah I see and there's your so

39:55 you have a gap that's where the airflow air flow comes

39:57 in through here through those what's the purpose of this gasketing um

40:04 we don't want any resin to if you did have a spill

40:07 to fall down into the printer so we try to keep um

40:11 yeah this section sealed you have an elaborate gutter system

40:14 to and ceiling to keep gut to keep resin out does it if

40:20 if resin goes in here does it then go Downstream somewhere else

40:23 or does it just go over it just pull in here it

40:26 pulls and then there's actually a drain um right there and it'll

40:33 end up going down into this cavity is there a catch thing

40:37 there's no real catch but it's fairly free of the things

40:39 that will get damage or stuff that's really easy to get to replace

40:42 um yeah this is another one of the things that it's it's

40:46 easy to overlook but it's like where if it if it shouldn't

40:50 and it doesn't never happens but if it did just theoretically where

40:54 would the resin go if I dumped a leader into this machine

40:57 it's really fun to test yeah the first time it's not

41:01 fun to clean up I'm sure but so you guys thought all

41:04 that through the resin comes down goes over here and goes out

41:07 this dedicated spout in the injection molded part down to a safe

41:12 space and then on your desk then on hopefully not that'd

41:16 be a big I I don't think I've really seen a spill

41:19 that big outside of our testing in the field maybe like when

41:27 came off or something but it's very rare very very rare but you're

41:31 covered okay so what next look at the size of this rail

41:38 that looks expensive is that a big part of the bill

41:41 of materials this rail it's actually not that big this is

41:43 a pretty common rail size um so they're made in such high quantities

41:46 that they're you can get it you can get them for relatively

41:49 relatively cheap yeah oh there's the screws wow exposed exposed Fasteners

41:55 on the outside that was also a big I'm a little surprised

41:59 did was there great arguments about these screws there great arguments about

42:02 these screws about what color this should be because it's not

42:05 the same color as the the rest of the part yes yeah

42:08 but we got every detail just just perfect everyone cares about their stuff

42:13 very much these are good these are good debates to have yeah

42:17 because it's always a challenge like what's cheap what's easy what looks

42:22 nice those are very rarely the same thing what's easy to use

42:26 there's no mention in like your development process you probably just

42:29 like made a bad product yeah yeah if there's not great debates

42:34 so this is just sheet metal powder coat or powder coat

42:41 yep it's interesting powder coat it's metallic why not uh that's aluminum

42:49 right that aluminum yeah so why not anodized uh anodization is hard

42:53 to get consistent over like many runs of batches of parts so

42:58 like this won't match that that won't match that you don't do

43:00 them at the exact same time yep yeah and then this part

43:03 is diecast uh so you can't anodize it and have it

43:06 look good you can try yeah it's not going to look do

43:08 your best but it's going to be bad what why does

43:12 your motor have tails uh those are just fan mounts so they're like

43:17 anti- vibration fan mounts so you just like squeeze the fan onto

43:20 them like a okay like a like a Gogurt tube that's funny

43:25 but all that extra material is being wasted shouldn't they be

43:28 half the yeah yeah the cost down opportunity here make these half

43:32 as long that's actually really clever hey those quarter of cents add

43:36 up four quarters of a cents there's four of them sense all right

43:43 so you've got a very large fan yep so this presumably is

43:49 for cooling yep and all the high power stuff Optics presumably not

43:57 Electronics yeah yeah cooling the Optics yeah we we're putting so much

44:00 Optical power through the LCD that there's a good amount of waste

44:03 heat generated so we have to try to dissipate it it's really

44:07 challenging because like you can't block this obviously you can't put something

44:11 here to block it so you have to just blow air across

44:13 it and try to get enough convection to pull all the heat

44:16 away did you look at different materials to try to get

44:19 better convection better heat transfer yeah we did we we were always

44:23 joking around about like having texture on the bottom side to increase

44:25 turbulence increase surface area yeah uh but that isn't great for object

44:31 did someone run a cfd of the airf flow to try

44:33 to make it even and we did cfds we did smoke testing

44:37 with like real smoke VAP yeah we blew sick Vape clouds

44:41 into the printer how hot does it get if you don't cool it

44:45 does it just kill it it kills it yeah yeah yeah yeah

44:47 if you're printing without any if you're printing fast at full power

44:50 without any cooling it'll get up to like 80 90 or 100

44:54 C it gets pretty hot yeah and you've got a a big

44:57 filter is that user serviceable yep yeah you can take the panel

45:00 off and this should just pull right out oh nice nice

45:06 little filter so so there's your mixer if I move this back

45:11 and forth really fast can I power it up can I make

45:13 it boot uh you can try ah you could do

45:19 that with the form to pick them up by the Yeah and it'll turn

45:23 on turns on by the time it drops do you guys have

45:26 do you know if you haveu to prevent that back driving I'm

45:29 not sure actually we can try it that's a great Easter

45:33 egg I'm just going to unscrew these I don't even know what

45:35 these go to oh oh coming off they have like white Loctite

45:41 on them or something okay what on Earth all right we'll get

45:51 to that is that the end stop for the mixer that's what

45:55 that looks like to me feel it yeah that's the end stop

46:01 so that's a beam that's a beam break for this that's how

46:04 you know where to stop right yep that's how we know what

46:07 the limit is and how what we used to home so

46:09 otherwise the motor doesn't know where it is so like if I

46:11 put it here it has no idea so when you start it

46:14 best to go until it detects that right yep there's a couple

46:18 other Easter eggs in there that you have to take the front

46:20 panel off to get to front panel next cut that hold

46:26 this fast so we've got a Raspberry Pi screwed to a big

46:40 form board but is that a custom raspberry like what is that uh

46:46 that's the Raspberry Pi cm4 what i is that what is

46:50 cm stand for a compute module okay so that's trying to be

46:54 like a system on module kind of thing exactly yeah yeah so

46:58 they sell this to companies like yep yeah they have a bunch

47:01 of different configurations of it um they sell it to to companies

47:05 and they yeah I didn't know they that's smart Raspberry Pi I

47:08 didn't know they did that I guess I don't need to rip

47:10 the Raspberry Pi off we'll leave it there that'd be great okay

47:13 I won't rip the raspber pi off um there's all man

47:18 the cable routing looks like a um a lot of work to get

47:24 right is there like just one big harness or are these all

47:27 separate these are all separate yeah they end up getting like

47:31 zip tied together in various places but yeah we don't have

47:34 one ma like massive arm yeah did do they work with you

47:39 to integrate this or is that you just got it has a data

47:42 sheet and you just do it yeah we got it and just

47:44 did it yep um and then we we all the the memory

47:48 and everything is on yeah our board so if we had

47:50 to replace the cm4 for any reason because that's like the most

47:53 complicated yeah you know error prone part so you push all

47:56 the as much not changing expensive parts off it so that you

48:04 can replace just that if you have to is that user replaceable

48:07 that's user replaceable yeah okay was that a a consideration HDMI cable

48:13 versus yeah yeah we want something that the the users would be comfortable

48:17 with placing if they needed to um all these little tiny

48:21 um LCD cables are really delicate really easy to break I've broken

48:25 probably more than I'm uh happy about um so yeah we want

48:31 to make everything HDMI is this a custom HDMI cable that's exactly

48:34 the right length or did it just happen to work uh it's

48:37 customed to be course it is yeah wow this is the motor

48:43 for the mixer stepper that's pretty big is that just the forces

48:49 of if you want to go fast and viscous materials you need

48:52 High Force yep exactly yeah is it on a vibration amount

48:56 no nope it's just solidly mounted not a problem right and then

49:00 the front panel wow okay so how much thought went into panel

49:08 attachment and like architecture for because you can see there's like crazy

49:14 the way this front panel attaches is pretty pretty interesting

49:17 with these I don't even know what you'd call that slots with screws

49:22 that almost pivot yeah so we're pretty conscious about panel gaps we

49:29 want to have everything as like tight as possible like um just

49:32 for Aesthetics so there's a lot of thought into like how

49:35 you assemble it and how you get this front panel aligned

49:39 to your side panels in the factory a lot SL tight slides

49:42 tight to the the side panels yeah whoa uh it's not sheet metal

49:48 trust like this hold on oh yeah this uh just because you

49:56 could this is what I'm seeing here hold on is that right

50:05 oh that really doesn't feel right okay there it goes go yeah

50:12 yeah so we try this is your Ultra lightweighting for the machine

50:16 this is our it's made of drillium yeah this is trying

50:19 to keep everything as light as possible for shipping is this didn't save

50:21 all that much but it was pretty cheap to do once you

50:23 tool that part so there's a a yeah there's a a stamping

50:28 tool that does this uh yeah I feel a bur it

50:32 must be there will be a stamping tool that does this yeah

50:36 yeah these these look laser cut so this closes up the mixer

50:40 so that it looks nice yeah and it prevents resin from falling

50:43 down into it so this has a big overlap with that if

50:45 resin gets onto this rail again thinking through all of the ways

50:49 resin can go down and everywhere should something that never happens

50:54 happens yeah think through all this this is a gutter thing

50:57 or a an awning it's like an awning yeah or it's like

51:00 a this is the awning and this is the like undercut of the awning

51:03 yeah it's a double awning yeah I honestly don't know why ibly

51:07 just like display power and oh yeah yeah signal conditioning or something

51:13 gosh he get a pop up oh it's the lever yeah

51:16 that'll do it oh you have an encoder W notice that yeah

51:26 very Co cool so this is a stepper it's a stepper yep

51:33 you're using the encoder to detect stalling early yep yeah yeah so

51:39 if we run into if a part falls off which it never

51:41 does and it did theoretically yeah we'd run into the part it

51:45 would stop the motor and we be able to detect it uh

51:47 with the encoder and that's so that you don't have to go

51:49 all the way back yeah cuz you could detect it just

51:52 by homing it every layer if you don't want to do

51:54 that yeah if you watch when it does motion we do what

51:56 we call mixer dodging where it Peels and does a synchronized motion

52:00 with the wiper or with the mixer um so we wouldn't be

52:03 able to do that safely if we didn't have um I see

52:07 crash detection yeah is that is that like a special quadrature tiny

52:12 quadrature module for this yeah yeah wow that's cool yeah that's nice using

52:18 the same PCB for both light based thingies there we go

52:24 we can actually look at it whoa are these solder on mounts

52:32 on the PCB yep that's cool so you have two two sets

52:36 of Vias and you just solder these lugs on and that mounts

52:41 to the frame that's nice instead of a piece of sheet

52:44 metal but someone probably spent a long time thinking about if you

52:49 should have a piece of sheet metal or these lugs or something

52:51 loose nuts or something else yeah yeah this makes it just easier

52:55 to surface to so you just take out screws and not worry

52:57 about dropping nuts into your printer yeah um and they're upside down

53:00 so resin I don't know resin can't get onto them yeah better

53:04 than right side up I guess cool and you tension the belt

53:09 the slots okay what's in here oh power supply power supply yeah

53:16 so this is like a certification double insulation thing so it's like

53:21 a fire safe enclosure yeah and this fin is for Co

53:26 the power supply so you have so all your air comes in here

53:30 you have some sucked up in here and then you also pull

53:36 some out that way y this doesn't suck air through the are

53:41 these cordoned off they're both are they both pulling air from there

53:45 they're both pulling air from there yeah it doesn't suck back

53:48 through here yeah but if this fan fails you're going to suck

53:50 dust you're going to potentially suck stuff so this this fan overpowers

53:54 this is like an axial blower yeah and so there's a whole

53:57 ducting system here to get your flow and the air shoots out

54:00 and then where does it go down cools your so using

54:04 the hot air to cool your electronics yep yeah the the air

54:08 doesn't actually get all that hot high flow cuz it's so high

54:10 flow exactly yeah so it comes and sweeps over the electronics um

54:14 and then can exit out um just kind of generally out

54:17 the seams in the back of the machine well there's a explicit hole

54:20 in the back of the machine yeah so when you take off

54:24 that cover magnet mag yeah is that really necessary it looks good

54:29 though doesn't it why does it need to come off uh

54:34 so you can clean it if you wanted to so it's like

54:35 we call this like the cat hair filter um so it prevents

54:38 anything from like really getting in there and clogging up but air

54:41 is coming out or this is the oh this is the inlet

54:44 I see okay okay let's see if we can get this uh

54:49 Blu out so you have another large fan with a big heat

54:54 sink so this this is for the LEDs themselves I'm presuming let

55:00 me get this off so we can see it oh little

55:12 speaker oh oh no oh no bear with me it's the one

55:22 with two wires probably yeah here we go got it the one

55:28 part from form two and three it's the Costas so you don't

55:36 have to take that off to get this out but what's

55:40 the purpose of this piece of sheet metal just holding the fan uh

55:43 yeah it just holds the fan in and I guess it directs

55:46 the air flow yep so is this is this cooling all custom

55:50 yeah this is all custom cooling so it's a custom heat

55:53 sink that's underneath here uh um and then yeah we're sucking

55:57 into the grate and then pushing out on either side of the machine

56:00 how much thermal design went into this uh a good amount yeah

56:04 that there's a lot of a lot of math a lot

56:06 of simulations um we didn't want to you know have to Tool

56:11 this big part and have to redo it a bunch of times

56:13 um so we wanted to get it right the first time is it

56:15 an extrusion or is it yeah it's just a big alumin

56:17 Extrusion okay yeah I mean it sure looks like an extr then

56:21 post machined you have to take an enormous amount of waste heat

56:24 away cuz they get super hot but then the light from them

56:27 is also a lot of energy so it makes the LCD super

56:30 hot because it it's probably absorbing more than 90% of the light

56:35 energy about 90 yeah okay that's pretty good and then so

56:39 that gets hot it can work but then die early presumably if it's

56:44 too hot so you probably had to did you do a lot

56:47 of testing y we did a ton of Lifetime testing of both

56:51 the LC itself um so that was you know blasting them

56:56 with with light uh getting them hot putting them in ovens uh

56:59 measuring them continuously over the course of many months making sure

57:03 they were going to last um and then once you do like

57:06 integration testing of bringing the whole thing together and making sure

57:08 that you didn't just break a cooling Loop by accident uh by putting

57:12 a panel where you weren't supposed to put a panel or like

57:14 you know putting a wire in the way that like blocks blocks

57:17 flow whoa oh and you have alignment pins for this too does

57:22 this ring my pins H there were there were talks about doing

57:27 fancier calibration at some point oh I see so if you want

57:30 to do light distribution calibration and stuff okay plastic molded custom I

57:38 assume Optics custom Optics power and then we've got what's fan okay

57:47 so fan is separate and that's that's it there's a diffuser is

57:59 that that's custom too yeah that's all so is this an injection

58:04 yeah I think that would end up being an injection flat

58:06 sheet inat sheet to get the texture and the shape and everything

58:09 yeah because it was like we already knew what um like acrylic

58:12 resin and stuff where we wanted for it so either have

58:15 to go extrude those for us or we just injection mold it

58:17 so yeah and the whole frame I'm this is the last thing

58:20 I guess we're going to dig into but then another challenge you

58:24 talked about it being stiff and the forces is so when

58:28 you peel You Yank up on the build platform so you have

58:32 the build platform that wants to twist this whole Tower wants

58:35 to bend and this is this is like a is this an extrusion

58:40 or what is this Tower the tower itself is an extrusion

58:44 okay um these are just cosmetic sheet metal kind of facia panels

58:48 to hide the cartridge and hide everything else Extrusion so there's a really

58:50 stiff thick aluminum Extrusion I thin walled but thick section to be

58:54 stiff and then that's bolted to what looks like two pieces

59:00 of sheet metal with like a square around it yeah it's basically

59:05 like a sheet metal box box oh yeah and this also closes

59:08 it nicely so there's five sides on it except for the top

59:13 and so that's a very stiff shape and really the main

59:17 force that you'd see yeah we bolt in from this direction under

59:20 the tower so we're grabbing it in I think four locations um

59:26 along the z-axis so it kind of helps to yeah find it

59:29 from twisting itself open or twerking itself open yeah yeah the like

59:33 clam whatever and it doesn't have to be super Square because

59:37 the build platform is adjustable right exactly I not crazy to assemble

59:43 you don't have to like put a micrometer on it and square it

59:47 up or anything you just bolt it yeah we don't need

59:49 to go crazy we need make sure it's Square enough that you don't

59:51 have your whole ZX just like drifting over the course of the print

59:55 um this NE calibrated that can be calibrated out it's not

59:59 but it's not we used to you get weird like pixel

1:00:02 things though cuz you're um if you have a straight wall you're

1:00:04 traversing pixels when you do that so I'm not even going

1:00:07 to bother to get in there but there's a force sensor that looks

1:00:11 really similar to the form 3 for I think the spring

1:00:15 is actually the same part and the pcba is same electrical design

1:00:18 but just kind of changed around to make it fit this actually

1:00:22 Four senses differently than the cartridge there's a spring that the whole motor

1:00:27 can move up and down on and then there's uh inductive sensor

1:00:32 inductive sensor right yeah so it detects the gap between the top

1:00:36 of the motor or the spring and there's like a Target

1:00:38 or something yeah there's a little Target on the motor itself and it

1:00:40 moves up and down it detects that distance and so when you

1:00:42 pull on the build platform the motor will get pushed or pulled

1:00:45 on and so then you can see how much force you're

1:00:47 applying to the part so you know is there a failure is

1:00:51 it did it rip the tank you know yeah we do

1:00:59 do like very fast control loops to make sure that we're not

1:01:01 going to apply a ton of force through the LCD screen yeah

1:01:05 yeah that's like the worst thing you could do yeah this is

1:01:08 taped together that's interesting why not screws uh well you can

1:01:12 see we put spots for screws um but we would have had

1:01:16 to modify the Extrusion this tool um that's another plastic tool yeah

1:01:21 you can't screw through to this H we could have but the tape

1:01:24 we did initially and it worked fine so he said just

1:01:27 keep with the tape ni is there any concern with it work

1:01:32 or the heat or anything yes we did testing to make sure

1:01:35 that it would be stable um under under temp um that was

1:01:41 that was a big concern uh make your way to like Buckle

1:01:44 change the distance to the LEDs or anything so what what made

1:01:48 this part you said this was really hard part what made it

1:01:51 part um I mean the optic design is tough right designing a lens

1:01:54 is is difficult than Des Thea gets 60 LEDs to be having

1:01:59 uniform power distribution is really difficult do you actually achieve that uh

1:02:04 I mean it's not perfectly uniform but it's a fairly uniform

1:02:06 like end result wow wow that's a lot thicker than I was

1:02:13 expected and we have to get all these lenslets centered over

1:02:17 every one of those LEDs so there's actually it's flx um located

1:02:22 so these pins help to get it kind of like averaged out

1:02:25 about each LED so okay so these little pins go into holes

1:02:34 on the lens but they're flexible they're flexible yeah AB if

1:02:38 you push them so like the elastic average of all those pins

1:02:42 makes the lens uh as censor as we can get it over

1:02:47 every LED you don't try to push it you want to try

1:02:51 to push it to or like locate against a hard D dur

1:02:54 then this must get super hot too think it's fairly hot yeah

1:02:57 do more thermal testing on that so you've got man those are

1:03:02 really small LEDs are they 365 or uh 405 405 really was

1:03:08 that to keep resin compatibility yeah yeah most resin compatibility was

1:03:12 that another big decision which wavelength is that was a really big

1:03:15 decision yeah so it's resing compatiability and then also LCD lifetime um

1:03:19 the lower wavelengths will degrade your LC's a lot faster so we

1:03:23 wanted to make sure that we had as long of Life Time

1:03:25 as possible and we didn't want to destroy res cage that was

1:03:28 probably not something there's data on you just had to do

1:03:32 a lot of testing uh yeah we did some testing on it um

1:03:35 to make sure that what we thought was going to be

1:03:37 true was true and yeah it turns out it was yeah always

1:03:42 ask when that happens yeah when you tried to make this so

1:03:47 you said all right we have our theoretical lens array the tape

1:03:52 from when you had that to when you had like working one

1:03:56 it's mess like out of the tool yeah so we actually tooled

1:04:01 just a single lens first um and we made um tile single

1:04:05 lenses that we could like kind of yeah get located properly so

1:04:09 that was actually pretty that's like um like a six weeks

1:04:12 or something to get get the first ones from like SAR design

1:04:15 and getting our first L is lit were the diamond turned

1:04:19 or was it uh molded they were molded yeah yeah yeah um so

1:04:23 you had to go make a bunch of them to make

1:04:25 one w right yeah expensive another part where it's cheaper to Tool

1:04:29 it yeah cheaper to do a small tool I had diffuser

1:04:32 on the back but then this final part was like this thing needs

1:04:37 to be flat right this is really tight like it all

1:04:43 these have to be right and it has to BU the very

1:04:46 very flat i i m it's warped you'll get yeah czy yeah

1:04:50 your Optics just won't be what you designed it to right all

1:04:53 your distances are F LS are ared well what's your what's

1:04:59 your favorite what was like the the best I think you said did

1:05:03 you say was the E with this it was this this that's

1:05:07 the heart and soul this is the heart and soul this is like

1:05:10 we simplified a lot of complicated um early prototypes into just

1:05:15 a solid state uh mechanical mechan op mechanical component that reduces Grill

1:05:21 forces and gives us you know like really good body with great

1:05:24 cool to be able to take a lot of like really complicated

1:05:28 electromechanical resistance and just like maybe

1:05:30 something solid state is the signal

1:05:32 inverse like CU it's transparent now so you're telling it does it

1:05:39 f the signal uh giv it like white images and black background

1:05:49 cuz normally LC is off right depends on depends okay LCD guy

1:05:57 every single one of these things you have to check to make

1:05:58 sure it works is what you're saying so even if you're not

1:06:00 calibrating you have to do it to make sure like the cable's

1:06:05 not disconnected exactly yeah even the fans have to turn the fans

1:06:08 on when sure they spin up do they just listen how do

1:06:10 you know uh these all tachometers in them it's yeah well thanks

1:06:17 for sharing all the juicy details yeah thanks for turn stuff uh

1:06:23 I could maybe reassemble oh thought that's going to happen going happen