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Manufacturing Update / Design Upgrades.

Posted on February 01 2016

Happy New Year! Hope everyone had a fun and relaxing holiday season.  We have a lot to tell you but first we want to mention we are still waiting on about 150 backer surveys. We need surveys completed so we know final order amounts and can put in our first product order, so please keep your eyes peeled for a reminder email if you haven't submitted your survey yet. If you have, thank you!

Now for the exciting stuff! We just got back from visiting all three factories that will be involved in the production of ThreadStax. Each plays a different roll in the final product: one factory produces the custom magnets that will be used in the slides, another produces the metal rails for the brackets and folder, and the third factory will receive the magnets and rails and produce the final product with large plastic injection machines.

 

Large injection mold machine needed for the larger folder side panels.

Upgraded design:

Slides:

Slide Upgrade 1) As mentioned in our last update we've redesigned the magnet cavity so now the magnets will be locked in mechanically, instead of glued, making them much more secure.

Slide Upgrade 2) Below are two 3D printed updated slides (please note the colors are not accurate due to the 3D process).  Top shows two stacked like normal and the bottom shows the new and improved way of stacking empty slides. We notched the back of the slide allowing them to nest and stack twice as thin when rotated 180 degrees from each other.  This helps reduce the product footprint when packaging for retail- as well has a saving space when storing empty slides at home. You now can stack your empty slides in either formation. If you're like me and only do laundry once every other week you may need to grab 10+ slides at a time. This makes it twice as easy!

New slide design (3D printer model) :  Top image shows two stacked normally; Bottom photo shows how they now conveniently nest together.
New slide design (3D printer model) : Top image shows two stacked normally; Bottom photo shows how they now conveniently nest together.

Folder:

The folder received a few upgrades as well:

Folder Upgrade 1) We added a hole on the top edge so that the folder can now hang on a hook. Just fold each side panel into the middle and it's compact enough to slide between your washing machines or hang on the wall.

Folder Upgrade 2) An added tab on the center bottom panel makes it easier to grab and fold when the folder is on a flat, hard surface.  The two side panels already curve upward and are easy to get you fingers underneath, but the center panel lays flat and this tab solves the problem.

Folder Upgrade 3) We upgraded how the slide locks into the folder. The old design worked but we knew it could be better. The new design adds two stoppers that have metal inside. This provides a visual target and the metal makes direct contact with the magnet in the slides so is much stronger than before.  This ensures fast alignment and secure positioning of the slide when folding.

Test Molds:  

The last variable that needed my attention was the hinge.  The  folder hinges needed to be easy to install yet hard to remove during use.  We made a test mold that had 2 variations of the hinges and produced several samples with different resin consistencies.  We were able to test several batches and find the perfect combination of size and resin for performance and durability. Here it is in action.  Note that the final color will be blue not clear.

One side of the steel mold
One side of the steel mold
Here is a test mold we made to test a few variations of the folder hinge to help us find the right thickness, density and durability.  The production mold will be very similar in size.  Over 150lbs of steel to produce such a small part!
Here is a test mold we made to test a few variations of the folder hinge to help us find the right thickness, density and durability. The production mold will be very similar in size. Over 150lbs of steel to produce such a small part!

eBook: 

I've received several messages asking about the eBook and when it will be delivered. I emailed the eBook on 12/07/15- I suspect many of you didn't receive it due to the size. It's a 90+ page PDF and might have been blocked by several email providers.  We've made a download page on our site for easy access.  Click Here to download.

Thank You

Thank you all for coming on this journey with us!  We couldn't have made all these design improvements without your support.  We'll keep you updated when the production molds are finished in the coming month and we start receiving sample production product.

-Scott Kosmach

 

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