This Machine Saves Me HOURS
ฝัง
- เผยแพร่เมื่อ 11 มี.ค. 2022
- We've been buying and building machines that help us make kits, and it's saved us SO much time.
You can get a kit here!: opulo.io/
Here's the belt cutting machine we bought: www.ebay.com/itm/402383044048
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LumenPnP Github Repo:
github.com/index-machines/index
Opulo Site:
opulo.io/
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PCB Holder: amzn.to/344qhVD
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Wire Strippers: amzn.to/2IESgDV
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Head over to opulo.io/ if you wanna pick up a LumenPnP!
Stephen, you can drop about $100 on a good HVLP sprayer, and some spray-able adhesive. that'll reduce the number of cans and time to coat for the foam. also invest in a good breathing mask and some coveralls
I would *love* to have the files for that belt winder, if you don't mind sharing them somewhere!!
You can add one more roller after 350$ cutter which can also wind it. If it is time consuming to add it electronically, just use mechanically, two GT2 pulley in a ratio to synchronise winder with cutter roller. Winder roller can be should removable(may be gear driven so that winder pulley stays in place).
Another youtuber who makes this kind of cutting & winding machines.
th-cam.com/video/kGyuscK9GaA/w-d-xo.html
th-cam.com/video/VW07FaIvl_c/w-d-xo.html
th-cam.com/video/Jl6ZATZypAQ/w-d-xo.html
th-cam.com/video/ZneBhLVsodA/w-d-xo.html
Do you guys need to assemble anything with screws? If so, get a screw presenter, and assembly electric screw driver that activates when pushed down. They can be set to a specific torque so you don't even have to think about it.
These seem great. Thanks! I wonder if the Lumen or something like it could use those to automate screw placement and fastening?
@@nidavis there are definitely robots that are built to assemble things and use screw presenters. The mechanisms that would be required to activate everything is in OpenPnp, it's just a matter of writing g code for it. Currently centroid files are converted on the fly for pcb's.
@@nidavis further, if something was designed in pcb software, screw locations could be loaded into OpenPnp with the "feeder" being the location of the screw presenter, and an actuator for the Z axis pick and place commands. The screwdriver would just be on the head instead of a SMD nozzle.
That being said, electric screwdrivers aren't light, and you'd have to accommodate for that. Nema 17 motors would have a hard time moving a screwdriver with any torque.
I made an automatic heat gun for heat shrink. I tore open a hand held heat gun, added an arduino, relay and two ultrasonic sensors. Sensors are mounted at the base of the gun with everything pointing up. Wave your hand over it and it fires up, remove and it shuts off. Saves me a ton of time for my business.
With the gluing jig you should attach the two bottom jig plates together with a hinge in the middle so you lift the both sides up and they meet in the middle. That would save the double work of putting in the second lot of taller locating jigs and lifting the second part out to place on top of the first.
Yes, I was thinking jig1 would have locating PINS that would jsut line upwith jig2, then put it on a hinge frame that just picks it up and over and down into the jigs lining up perfect.. no more needing to put those smaller items in the foam to line up. could even make it where the glue shields are on hige mechinisms too that fold on to glue and fold out when done and fold the foams together... could make doing that job down to about 10-20sec per foam set..
You can get some decent wire cutter and stripping machines, wire terminal crimper machines, and heat shrink conveyor ovens from China if you plan on making wiring harnesses.
Having worked in more than one startup in the early growth phase before, just remember that when you reach a certain volume you have to stop trying to do everything yourself and start using external suppliers. You're not there yet, but have it in the back of your mind that things that are not your core technology don't HAVE to be an in-house thing. The day you have too few people to package and ship the product efficiently, don't hire even more, but consider outsourcing something like the foam inserts, and have the guy who was making the foam inserts help out with shipping instead, etc.
As someone currently in this stage oh man yes.
Perfect! Know your strengths and know your weaknesses. And don't let your weaknesses become a chain holding you back.
*This may just be me*, but wasn't a lot of the Philosophy behind the Open Source Hardware / Maker / Mid-Scale Manufacturing movement to keep things local / in-house?
Thus having resilient microfactories/makerspaces, not Ballet like hyper-globalized supply chains that can collapse like a house of cards?
@@ericlotze7724 The only thing they produce truly in-house is software, and the design documents/files. The circuit boards, the semiconductors, the metal extrusions and plate, the stepper motors, the timing belts, the wires and tubes, the cardboard boxes and foam, the nuts and screws, etc. all originate from external suppliers.
Opulo sells a product that enables makers, people who usually produce small one-off batches on a tiny scale. The tools used by makers are superb for making prototypes and rapidly iterating for R&D and product design. They are also great at doing small-scale production for the first months or year of a startup, unfortunately, they scale terribly when you start getting hundreds of orders per day.
There is no reason for them to restrict themselves with such limited tools if the goal is to have a LumenPnP in every makerspace around the world, similar to what Prusa has done with the 3D printer.
Tooling Engineer here, do what you can to avoid getting locked into a set with a non-modular design because you're gonna inevitably want flexibility to change your design. Ruled dies are an order of magnitude less expensive than rotary. Have you thought about making a custom hot-wire foam cutter? You could have multiple wires spaced out to cut the same part multiple times in one cycle.
Anyways, love your channel.
A quick way to clean the jig stencils is to mask them off with craft paper and tape. It is an old airbrushing trick I've used back in the day.
I feel like using a roller (like a paint roller) to roll the paint on might be more efficient than using your jig. If you roll from the bottom then you won't drip the glue onto the foam either.
hah yes. this is one of those things where you get stuck in a solution and don't stop to think of an alternative idea.
How would you apply glue with roller from bottom, the foam is quite soft
Modify the winding jig and attach it at the end of the cutting machine and you will have one-stop shop belt cutting and winding.
Was thinking the same thing
Cover the stencils in blue painters tape. When it gets gummed up you just peel it off and reapply.
Rotory is good for massive high speed production where you need several cut per second, Panel die cutting should serve you well for a while.
That belt winder is genius!
how about a belt cutter and winder combo?
Can I just say - your enthusiasm for the machine and for all the nerdy stuff is contagious, and it's a pleasure to watch you like that! Quite refreshing :)
If I do ever buy a P&P, which is somewhat likely with my eventual plans, it'll be this one for sure - just seeing how caringly it was built and all!
One small side-question, is there a Plugin for the P&P control software you use to interface with something like Part-DB?
It would be very useful to link up the machine to a part management tool to track component use including "failed" component grabs.
So yeah, I just binged this entire series, despite not having any reason or plans to own a PnP machine. It's pretty awesome to see the development progress of something that's complex, yet simple enough to understand. Very interesting project, and very cool to follow along!
Maybe silkscreening a glue onto the foam would be an option to avoid spray adhesive (expensive and not particularly environmentally friendly).
The glue for the silkscreening would have to be quite thin but there should be options available.
paint roller. or a CNC glue applier
On the gluing jigs, you could place some thin adhesive plastic sheeting over the jig, then cut out the areas that aren't blocking glue. Then, when you need to clean the jig you just peel the plastic off and put on another sheet. The cutting out would take a few minutes, but would greatly reduce time and cost and be safer than using solvents.
depending on "protective" sheet you put on, a lasercutter was standing with there. pop off old gummed up sheet, put on new fully covering foil, run throught laser (indexing pegs are already in the jig, maybe add some indexing to the cutter?) run job, continue glueing.
or apply glue with a roller...
... semipermanent mold release on the stencil. It's designed for composite molding & the thick adhesive layer will just peel off when you get tired of the gunk. Think commercial-grade RainX.
You might even get away with a ceramic-based car wax.
The jig is made by wood which is already very cheap, throw the used one and laser cut new.
Would it be bad if you just made the rectangle of foam under the staging plate as a separate piece? Then the whole thing could be one-piece thicker foam (with no glue), and the rectangle would drop in. Just a quick thought tho
BTW great work guys! love your vids
you might want to tell us what takes you a lot of time so we can recommend helpful machines
also I think a cnc machine with two connected arms that cuts either styrofoam or I guess foam like the styrofoam cutting machines you see on youtube might be usefull since you could both layers at the same time and didn't need to glue anything together, which seems like it would be a huge timesaver
but its probably more of a project than a solution so not sure if its worth it
I think a full breakdown of the kitting process and how much time every part of it takes could be an interesting insight into the mid-scale manufacturing life!
The cutting machine needs a name.
Have you considered converting the LumenPnP, or the CNC laser to spray the glue? With machine spraying close enough to the surface (maybe with a custom nozzle) you wouldn't need the stencil
This is amazing. Your story reminds me so much of my early days in an electronics R&D startup... So much hard work but also so much fun. Hope to see this company grow, and would actually love to get my hands on a kit!
You could coat the template with a silicone spray or beeswax then peel the adhesive off.
I've tried commenting to suggest a particular brand of machines that have been super helpful to our production at the place I work.
We have their wire bending, cutting, stripping machine (yes all in one) and their automatic tape dispenser. Both work awesome.
The brand name is kingsing
Love seeing efficiency tweaks!
Awesome stuff...i like the fact that you document personal as well as your business growth over time....Besides the content you share, i get lots of value out of your decision processes. Keep it up, always excited when i see a new video from you guys. May your business prosper in the days and years to come...Lukin forward to the bext video
Amazing to see the progress you're making - it would be AMAZING to hear more about the process of hiring staff. It's such a big step to take, I'd be really interested in hearing how you found the process.
You can just glue one side of foam and it is better to use a roller with no stensil rather than a spraygun . Great job 👍
they're using a spray contact adhesive. it needs both sides.
Use of roller both sides still works and is much simpler it would seem.
@@adamjackson9988 ah- except a roller would coat everything, and they can't do that because they need it to make a shelf for a part, not just a thicker piece of foam.
@@SignalJones but they are laminating 2 pieces? They make small rollers
@@adamjackson9988 yes, but that requires more skill than foam, stencil, spray, stencil off, place.
i thought the auto cutter is overkill but then you showed it cutting heatshrink tube
yeah that'll get tedious very fast
Thank you Stephen for documenting your progress and processes in such a clear and engaging way! I've been getting into small scale manufacturing and product development and your videos have been really helpful and inspiring. Best of luck in getting your first employees up to speed, and definitely looking forward to hearing more about how you went on about hiring and how you manage the company scaling up!
Awesome belt winder! It might be even faster if you replace the crank with a motor connected to a limiter switch precisely positioned next to one of the spools. When the spool reaches the correct number of turns, the wound belt contacts the switch which stops the motor.
Add a cutter mechanism so it winds and cuts.
Continuous unattended operation might be tricky without a way to keep the material coiled. I'm envisioning a magazine/cassette mechanism with about a dozen slotted holes for the coils to drop into. The holes could be arranged linearly, or radially like a DVD jukebox. Once the coils are in their respective slots, ziplock bags could be lowered (by human) onto each coil.
Skipping my magazine/cassette binning process would be better if you could figure out a way to bag the coiled material directly but I am not smart enough to automate working with ziplock bags.
When are you going to provide an update on the feeders?
Love it. Been wanting to get an automatic wire stripping and cutting machine. Ideally it'd also crimp but the ones that do that are way out of budget.
It's sorta funny that they bought a machine for this, it seems like the type of thing they should be able to slap together in shop honestly
When i saw your glue jig I thought you might do something a little more similar to what a commercial silk screen kit looks like. I think it might be worth considering!
you should extend the top guard with a 3d printed attachment on of the cutting machine so it doesn't get caught up in the machine
I was hoping for a diy foam cutter.
Love what you're doing, great stuff.
Sooo exciting! Very stoked to follow along with you an Lucian!
Superb ! Thank you for making this. I’m trying to bring a mechatronic product to market - and the working out how to do all this stuff is the bit of the design process “I wasn’t expecting” - and your video has certainly given me some inspiration - ty ! I have subscribed … :) this is the only video I have seen that I seems to be resonant with what I’m going through … hence inspirational. It seems everyone has these problems !
I was wondering how long it was going to be before you had to clean off your stencil.
In automotive paint shops the buck/carrier/skid (every plant seems to have a different name for it) goes through the paint booth a number of times and then it has to be cleaned off. The way that this is done usually is by blasting it with 12K - 40K PSI water. Which along with the mess and constant maintenance, emits a horrendous amount of noise. Probably not something your neighbors want to hear. And by neighbors, I mean anyone in a 1/4 mile radius.
Another option is to burn it off either in an oven, or get this, molten salt. Yeah, you don't want to go there.
Solvent is bad in its own right (flammable, not healthy to breath, and if your operation is big enough then you are expected to pull a permit and treat the fumes).
If you do decide to burn off the glue, I suggest that you do it like the big boys do, and do that operation at night. Just saying...
So how about a thick coating of grease? Or just bite the bullet and make them disposable.
Or just use double-sided tape and be done with it.
As for cutting your foam, we used a water jet to cut the carpet going into S-10 trucks at the Shreveport plant. That process was impressive, the carpet wasn't even wet after getting cut. However, if you think that lasers are hard on fingers... And robots aren't wallet-friendly.
Possibly a better way would be to ditch the environmentally unfriendly foam and go with stacked sheets of carboard with water-based glue.
This is where getting a packaging engineer involved is a good investment.
Lots of good ideas here.
With the gluing process, I think we can all agree that excessive glue is wasted material and cost. Excess ultimately becomes scrap that requires additional cleaning processes so it's best to minimize the wasted glue, if not eliminate it entirely.
I like the idea of eliminating the foam. It's surprisingly expensive and doesn't really add much value to the customer. One alternative is vacuum formed plastic. It is surprisingly easy, fast,, and inexpensive
@@brad3378 I hadn't thought of vacuum-forming plastic. That would work well.
Great to see how you and your team , take it to a new level
Next time take the spool, attach one end to a spool on a drill. Have marks on diameter to know when to cut. slide off half spool place in bag. This would take 15 minutes to design.
Stepper motor and arduino for precise, repeatable length cuts
That's awesome. Those are things we don't want you wasting your time on.
This makes me realize there are far too few industrial machines with "fun" buttons.
Impressive development
Thanks for sharing your experience with all of us 👍😀
Fun to see automation ideas.
There’s a machine that counts, and bags small parts, they even do them that do multiple different parts.
Interesting - any suggestions of a brand / search terms or a link …? I have this problem looming in time too !
@@jonnyhifi I don’t have any brand suggestions, they are kinda made to order, can range in cost from £1k to £30k depending on need. - There are a few DIY models on TH-cam though, search ‘part sorting machine’
@@jonnyhifi they all work in pretty much the same way, vibration or spinning parts to separate them, then mass or sensor counting them, mass ones are less accurate because they rely on a regularised mass of the part, and sensor ones tend to need more customising for part shape.
Interesing insights. Thank you 😊
Thanks for your generosity , amazing what you can do thinking out of the box, Thanks for sharing.
If you hinge that glue stencil you could minimize the alignment time even further
put a set of hinges on your stencil so its always aligned
I am always smiling when i open a box and there is no foam or styrofoam inside and instead some eggcarton like piece!
Fantastic!
If you need tape cut to certain lengths, there are tape cutting machines. There are a couple types depending on your needs.
Really nice machine
at works we have almost the same cutting machine, we cut some heat-shrinkable tube, ground braid, shield for some applications,...
You can get screw sifting jigs that have slots for exactly the number screws you need to package, just shake, dump and done.
he could even print them
@@l3d-3dmaker58 "get" wasn't intended as purchase, easily fabricated.
This is great.
Also "your boi needs a trim"
Well, you have that convenient material cutter setup nearby, just set the length to 0.4mm or whatever you prefer, and... OK, maybe not stick your chin in it.
First and foremost interesting topic. In the CNC manufacturing world. A worker will only tend a maximum of four machines. Off course duty times is important, and yes automate helps, but it can be very tricky to make a full automation system. The solution is of course collaborative robots, and workstation with Line. With a minimum of transportation/sorting. So that you can controlled the R & D for the automation. All this and yet still being able to be flexible is incredible tough. That level of complexity cannot be build in the midst of a production start up.
Hang in there and as soon as you get the time think about the system as a whole.
Okay but why use foam when you can use a single large folded cardboard cut-out? In a lot of cases you don't even need to do the unfolded design yourself because SW like blender can do it for you as long as you have well designed packaging.
I like your clever designs, very nice, instead of the machines you could have used a stepper motor, thus when it unrolls onto another roll it knows when to cut
we have simmilar cutters for wires at work, not sure how much different the cutting part is, but basicly the same (just more expensive i imagine)
Our cutters would support a serial controller, dependign on requierd throughtput, raspi with servos to pull the feedign stock back a bit so its not in the rollers, run job X until stock runns out or number is reached, switch stock, run Job Y, Job Z, wait for new stock. repeat? most likely not practical though for various reasons
Could you maybe modify an lumenPNP to help make kits, like picking fixings, nuts and bolts and putting them in little bags?
Where did you buy your cutting machine?
I would love to work for you! hope the new peeps get up to speed and help grow your business
Dream job right there I'm super jealous
Ah, the essence of lean manufacturing
yeah boy!!! automation rules!
Another reminder building hardware products are half the product and the otherhalf othibg things
You can maybe use a screw counter
Where did you get the cutter from for $350???
Nice!
he seems kinda obsessed over all his kids, so lovely :D
... or was it kits ;)
Can someone set up a site where you can order PCBs in a decentralized way? (Basically the owner of a machine can make the machine available) I would really like to use that eventually.
that's a very very interesting idea! with enough of them, you could source your PCB from a local machine and not wait for pcbway assembly and shipping!
Philipp are you talking about PCB manufacturing or assembly? Consumer-grade printed circuit boards take more than one machine to make, and there are very few board houses in the US. It’s not like 3D printing where there are a huge number of hobbyists with them and we just need a web platform to decentralize existing manufacturing capabilities. Assembly is another issue entirely, as you need the PCBs to be in a compatible PnP machine that is loaded with and can accommodate every component in your BoM. Traditionally, small-scale PCB assembly works by sending the board house your BoM and they’ll then source and invoice you for reels of each component, then send you the surplus components with your order. It doesn’t make sense for them to hold onto specific components you need for your board in their inventory in hopes that someone else will need the same component. JLC is able to simplify the process by having reels of the 1000 most commonly used components pre-loaded into PnP machines. They can be confident that they’ll be able to use the surplus, so they don’t need to source and invoice the components individually for each customer. If you have a component that’s not on that list of 1000, they can’t assemble your board because it doesn’t make sense for them to set up a PnP machine for one small custom order when their fleet can handle more common orders much more efficiently. Until there is a fundamental shift reducing SMD components to their building blocks, allowing a wide variety of components to be assembled from a small number of unique blocks, and we have machines accurate enough to PnP them, PCB assembly will be limited by these inventory and supply chain issues. And I think that’s an idea worth sharing, thanks for coming to my TED talk lol.
@@griffinvanhorne8695 I also know that JLCPCB does this. Problem is just we currently have a war and I am not very sure what side China will stand on. I am not willing to rely on China for this.
Philipp it would definitely be great but I don’t know how realistic it is quite yet. The cost advantage of PCBs and SMD components made in China makes it hard for international competitors to survive. Opulo is making strides toward allowing bare PCBs to be populated affordably in small workshops, and this could allow for a JLC-style PnP farm with a massive inventory of components elsewhere in the world, but decentralized assembly is still dependent on one single node of the network having a large inventory of components. In the meantime, this machine will be perfect for setting up for a few specific boards with a limited BoM and cranking out hundreds to thousands of them. Maybe the political climate, freight cost increases, retaliatory tariffs, etc. will make domestic manufacturing relatively more affordable, more domestic board houses open up, components can be sourced relatively more affordably domestically, and there’s greater demand for domestic quick-turn PCB assembly. The other option is to join or start a makerspace where you can split the cost of digital fabrication equipment like this machine. That’s probably the next realistic stepping stone.
ebay link doesn't work, can you publish actual link or machine model?
Let it drop in a BIG box on the floor :-)
What does the FUN button do?
Seems like it's the DG-100B. Still 600 EUR + tho
What's that headphones mod you have?!?
Ok, what does the "FUN" button do?
Don't forget your free stuff when you order through ULine. I have so many ULine Maglites and headsets.
I’m holding out for that Yeti Mug 🤤
Too bad the fancy tubing cutting machine won't actually spool up the output for you too!
I wonder if your friend with the PCB contracting factory is intimidated by the OpenPnP? I would be.
What is the FUN Button for???
Apparently it's for "Function" aha
Hope it is going well, shared you last video to an AI group. :)
Please don't use foam for packaging! I'm sure it's not easy to replace but you should try to find an environmentally friendly solution.
Super true, we're also looking at getting folded cardboard packaging to replace the foam! The foam die will help us in the short term, but we're definitely switching to a more sustainable choice! The way Prusa kits arrive with mostly folded cardboard and some recycled foam inserts is the approach we're considering.
@@stephen_hawes I don't work in packaging, but mycelium (mushroom-based) is a recent option I've heard about that might be worth at least a cursory look.
@@eliotsandberg8979 they looked into mycelium. One of the main issues for them is that 1) it takes like a month to grow, and 2) you need a lot of molds, which adds up in price.
They wanted to hold off on it until they have their packaging decided pretty solidly. Then they might consider it.
@@natalie5947 First result in google reckons it grows in 7 days, but that's still way longer than bending some cardboard and whatnot.
Thanks for the info, and fair point on needing a lot of molds :-)
@@stephen_hawes That's good to hear, I was thinking of the Prusa packaging too. great to see you make progress with your company
I wonder what the FUN button is going to do...
Look at ziptie guns. These are cheep handheld tools to install zipties much faster. Don't know, could be usefull or something.
First! First time ever!
congrats (?)
Well done, feels great doesn't it?
You've spent a lot of time designing and testing your packaging. Would grown mycelium foam offer any benefits over your cut and glue foam method? th-cam.com/video/HqmCSml15jU/w-d-xo.html
There seem to be several companies offering this technology, not just the one I've linked to.
If you're in business it behooves you to hire lazy people. Now mind you not lazy as in slothful but someone who's always looking for ways to work more efficiently.
Pretty cool video guys.
Please replace the foam with cardboard. I don't mind plastics used on components for a machine, as those will be used for a long time, but I really hate single-use plastics. I think most of the methods you're using are fine just replacing the foam by sheets of cardboard. Also, you can stop using glue if you make the outer shipping box the exact size of the cardboard sheets, as the box will make the sheets align without needing to add adhesives. And buy boxes that open from the top, not the sides, to make boxing easier and faster.
Dude why are you using other youtubers intro music?
This fellas got into the bottle of happy pills.
Could you put a pause between your sentences? At the start of the video you edited your sentences back to back, I don't like that.
In the beginning was the Word, and the Word was with God, and the Word was God. 2He was with God in the beginning. 3Through him all things were made; without him nothing was made that has been made. (John 1:1-3)