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Update: reproduction parts



#13

in a thread below i mentioned we were considering manufacturing some HP41 repro parts (module port covers &
battery port covers firstly); well, the moldmaker wanted
$2K+ (doubleouch!!) for each mold; this is way too expensive
to even consider using this method that its out of mind;
trying to figure another method of making a mold directly
from the part that would be usable w/ the injection machines
but its possibly impractical. we will still attempt to
try to figure a method that might be usefull, and i will
post if we come up w/ anything.
tnx to all who responded!
barry
carson city, nv


#14

I wonder if it would be possible to make fiberglass parts?
That should be much easier, shouldn't it?


#15

yes iqbal, i will be looking into various other methods of
making parts, including fiberglass - but 'glas will be hard
to do w/ these smaller parts.
tnx,
barry
carson city, nv

#16

I think your only practical alternative is laser stereolithography. A laser beam is scanned over a vat of photo setting polymer and the part is built up as a tray is automatically lowered into the vat.

#17

Hi,

A college of mine is a specialist for r/c ship models. He told me to make such things from "resin". He showed me some parts he made. They where absolutly great !!!

Perhaps this can help you !

Best regards

Andreas


#18

One of the common problem with the 41's is the Battery I/O Assy - especially the flexiable PCB, can that be reproduced? I am sure many of us would need a replacement.

Regards,

Y K Wong.

#19

yes, this will be the next method to check out; it could
prove useful!

#20

$2K for a injection molding tool for the HP41C port cover isn't unreasonable. A tool for the battery holder should be much more expensive. There are ways to cut costs on injection molds - was the quote for a steel or an aluminum tool? Epoxy tools are also possible, provided you don't need that many parts.

You really want to end up with a part that has a reasonable color and texture match, and that also has a reasonable chance of snapping in properly. I have experience with other prototyping methods (stereolithography, selective laser sintering, rubber molds to make urethane parts) and they could work, but they will need sanding and painting. You will also need to generate an STL file from a solid modeling CAD package such as Pro/Engineer.


#21

this was for a steel mold, and that was w/ us supplying the
mold base itself; the $2K isn't unreasonable, but when u figure in how many parts you would have to sell to even make back your investment, it just ain't feasible (if you want to
keep the price of a port module cover in the $5.00 range).
Basically, standard production methods will involve too much
expense to make it worthwhile, you aren't going to sell 300
or 400 port module covers; unless you were the moldmaker yourself (and were running the shooting, too!) the math
just doesn't work out. Figure you would sell MAYBE 100+ covers, so it just isn't going to work out via injection
molding.


#22

One way to help cut cost would be to make several different parts in the same mold rather than making several molds. The math still doesn't add up.


#23

the cost isn't in the mold base (which we have many of), but
in the reverse engineering in making a print of the part to
be manufactured, then CNC'ing the base, including all necessary passageways needed to flow liquid plastic correctly, draft angles for correct part removal, etc. there is much more to it. when u realize what these tool & die makers charge/hour it becomes expensive, especially for a knowledgable one. look at a port module cover as if u
had to machine one and the problems become apparent.
barry
carson city, nv

#24

I haven't read all the posts in response to this one, so maybe my two bits won't be very original, but here goes:

I wonder whether someone with hardware savvy could come up with "plug-compatible" battery pack replacements -- maybe lithium-ion high-capacity units that deliver the proper voltage, serve as the appropriate load (when necessary), and have recharging jacks built into integral battery covers?

For instance, a "3-N" package for the HP-28 calculators would be great -- less-frequent battery changes might help the battery-door-to-case attachment points live longer.

Or a "4-C" replacement for the HP-97? (I mention that 'cause I haven't gotten round to rebuilding my 97's battery pack.)

It would be great for those of us who occasionally USE some models to have long-life rechargables that would help extend the calculators' useful lives.


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