Welcome to the first foray inside the oomlout.com factory. At oomlout we are focused on producing "delightfully fun open source products" this commitment to open source extends to our manufacturing process as well. So what follows is step by step what we go through to fulfill an order using our Arduino Controlled Servo Robot - (SERB) kit and an order size of 30 as an example. You will find everything you need to get up and making your own SERB's in semi industrial volumes, ideally you won't decide to. the real purpose of this Instructable is to act as a repository for our methods, jigs, and tricks and to help anyone looking into producing similar style kits. (or simply for those who like to see how a product is made).updates to comeThis will be an evolving Instructable to be updated with new tricks as and when we come up with them. Hopefully slowly changing from the small tabletop factory we now operate towards something much grander.The steps to followWe have broken down our manufacturing process into five main categories each with sub-steps.
Step 1: The Product
First off what we will be making.We will be producing 30 Arduino Controlled Servo Robot - (SERB) - kits. The SERB is our open source Arduino powered robot platform. Details on how to make your own can be found- (here)Or if you'd like to purchase a kit they can be bought from our online store - (here)
Step 2: Tools
Our ultimate goal is to have our very own oomlout rouge (except with less environmental impact). What this means is trying to bring all things feasible in house. Reducing dependence on outside suppliers allows us huge flexibility as well as keeping our costs (and ultimately the price of our products) as low as possible, however this does come at the expense of a degree of polish (apologies for no colour packaging). The Tools:Laser Cutter - (Brightstar LG3040tt 35 watt Laser) (details)
Step 3: Materials and Suppliers
Rather than recreate the parts list here, ordering parts is as simple as going (here) and multiplying each item by 30.In addition to the robot parts we need to throw in a few additional packaging items.Packaging
Step 4: Laser Cutting - Large Sheets to Little Sheets
With everything prepared lets get going. (attached to this step is 03-OPNM-Acrylic Cut Summary.pdf this is the formalized steps we go through when manufacturing)
The first step involves taking the full 4' x 8' sheets of acrylic and reducing them to a stack of 9.5" x 9.5" sheets.
This is quite straightforward, if not slightly time consuming. Set the table saws guard to 9.55" (a little extra for safety) and saw away.
This creates quite a lot of plastic chips and an awful smell, so an exhaust fan is a must and vacuuming of each piece afterward is also called for.
03-OPNM-Acrylic Cut Summary.pdf(612x792) 11 KB
Step 5: Bulk Stripping
With all of the rough handling done we remove the protective sheet from both sides of the acrylic.
This is one of the funner steps as you can make any number of bizarre noises by peeling it every which way.
Step 6: Sticker Sheet Cutting
Just one more step before we fire up the laser.Removing pieces from the laser can be quite a struggle if done by hand. To get past this what we do is lift everything out by using a sheet of sticker. This makes removing the pieces from the laser quick, and also gives the final product a very neat feel, as all the extra acrylic bits are also shipped.To cut these sheets we have a specially built machine to measure out 9.5" strips. (details can be found (here) ).A quick video of it in action (here)
Step 7: Setting Up the Laser
This step is crucial to the entire process working smoothly. What is involved is taping in a piece of acrylic and cutting an "L" out of it so you can place your acrylic sheets at the origin of the laser. This jig allows you to quickly change pieces without having to reset the machine coordinates between sheets. (details)
Step 8: Cutting
Finally the time has come.Place in a sheet, close the top, and press start. What follows is ten hours of every ten minutes (60 sheets) lifting out the cut pieces, replacing with a fresh sheet and pressing go.To help with timing we use a little program (egg timer) which plays a wav file when it runs out and allows you to do other things while the laser is at work.(we fill all the little hardware envelopes)
(V 1.0) SERB Laser Cut Layout (9.5).cdr39 KB
Step 9: Finished Cutting
Ten hours has elapsed and you have completed all your cutting.
Step 10: Hardware - Printing Envelopes
While the acrylic is being cut you have plenty of time to stuff the various envelopes full of the goodies that come with each kit.We start by printing what is inside each envelope. As the envelopes we use (#1 and #6 Coin envelopes) are quite a bit smaller than normal mail envelopes finding a printer that will print them happily is nearly impossible. Our problem was solved when we happened across an old ink-jet printer at our local thrift store ($2.50). It's absence of a paper presence sensors, and easily modified paper feed tray made it perfect.Quick Envelope SummaryENV 01 3 mm Hardware - small
(ENTL) - Large SERB Envelopes.cdr47 KB
(ENTS) - Small SERB Envelopes.cdr18 KB
10-OPNM-Envelope Summary.pdf(612x792) 11 KB
Step 11: Nut and Bolts
Envelope #1 (3mm Hardware) - if you are counting each item one by one this envelope is painful to fill. Because of this we purchased an old laboratory scale and now measure by weight (ensuring a twenty percent safety margin, we don't want anyone being short a washer). Add a couple of acrylic funnels and envelope filling becomes quick and painless.Envelope #2 (8mm Hardware) - With only a couple of large items this envelope fills quickly Bolt Weights
(ACFU) - Acrylic Finnel For Bolt Handling.cdr20 KB
Step 12: Arduino and Breadboard
Envelope #3 (Arduino) - This envelope is slightly more complicated than the others in that we pre-load each Arduino with a test program. To do this we slice an opening in the antistatic package and load "_SERB_Test.pde" onto each board before sealing the opening with an oomlout sticker.Envelope #4 (Breadboard) - Simply slip the breadboard into the envelope.Attached Files:(V 1.0) SERB oomlout labels.cdr - Labels used to cover up the cut
(V 1.0) SERB oomlout labels.cdr23 KB
Step 13: Wiring
Envelope #5 (Wire) - This envelope takes several steps.
(BACL)-Battery Clip Jig.cdr17 KB
Step 14: Servos and O-rings
Envelope #6 (Servos) - Just one step before stuffing these in their envelope. Drill two 1/8" (3mm) holes in the servo horn to allow attaching to the SERB's wheelsEnvelope #7 (O-rings) - Slip the O-rings in and close the flap.Congrats your Envelopes are stuffed, your acrylic is cut, and you're ready to produce instruction booklets.
Step 15: Instructions - Printing the Booklets
To keep things in house and costs down we produce our instruction booklets on a laser printer.Doing this takes only a few simple steps:
(BOST)- Booklet Stapler.cdr17 KB
05-(SERB)-Wiring Diagram.pdf(612x792) 54 KB
04-(SERB)-Assembly Guide.pdf(595x842) 1 MB
05-(SERB)-Wiring Diagram (Cover).pdf(612x792) 169 KB
Step 16: Packaging - Getting the Boxes Ready
We are all but complete. Time to get everything packaged up and ready to ship.First off the boxes.
(V 1.0) SERB Packaging Cover.pdf(612x792) 85 KB
00-SERB Packing Summary.pdf(612x792) 54 KB
Step 17: Putting Everything in the Boxes
It all comes together simply follow the packing list below, add packing peanuts, close, tape and repeat 30 times.Packing List:
Step 18: Final Quality Control
With the utmost care taken at every step this one is really not necessary. But in case a simple mistake was made and it is easy to catch we weigh each completed kit. As a result you can be certain that the kit you receive will weigh somewhere between 852g and 859g.
Step 19: Finished
You've done it, produced thirty kits, all that is left is shipping them out. I assure you the nuances of shipping require at the very least an Instructable to themselves so i will leave you with inventory.If you have any questions, suggestions or would like clarification on anything please feel free to leave a message or send us an e-mail at firstname.lastname@example.org.(shameless plug)or if you'd like to check out our delightfully fun open source projects trying visiting oomlout.com