Update #15 – Ship hold lifted, 3D Printable Tooling
Last Friday, after more drop testing for our packaging validation and after another round of test shipment, we decided to lift the ship hold. As of right now, virtually ALL of the $45, $65, $100 and $300 rewards for the lower 48 states have been dispatched. This represents approximately 80% of domestic US orders. Unfortunately, Fedex’s shipping system barfed on this shipment, and shipment notification emails didn’t seem to have went out. That being said, the packages are already enroute and some may be delivered as early as Tuesday, July 17th.
We have commenced shipping tests to Hawaii (via US Postal Service) and to a few lucky folks overseas in the European Union as well. With postage 5-6 times higher for international orders, it’s important that every package, every customs form, etc, are throughly checked before the package goes out.
Currently outstanding domestic orders are:
* $200 and $375 “Limited Edition” rewards. The paper for the engineering prints just arrived today, I’ll run the prints (close to 500 pages!!!) and sit down to sign them with a big ice pack for my wrist.
* KS0125 Camera Kits – Screws just arrived, we need to kit up the laser cut camera mounts that ship with these kits.
* Trebuchet Kits – on back burner until the international orders are out.
* $1024, $1100 and $2000 kits – we are repackaging the extrusion bundles for these kits, especially international shipments, to ensure that the extrusions arrive in tip-top shape.
* Missing / damaged parts – we will be dispatching these via USPS Priority mail for missing components and Fedex Ground for damaged extrusions / kits this week.
When you receive your package, assuming it arrives in good shape, I’d appreciate it if you can leave some positive feedback on the project page here. I am trying to build up my reputation for my next Kickstarter project… 
Someone had asked about what we do in a drop test. The answer is simple:
1) We establish a documented procedure for packaging and we package up 20 pieces of black anodized extrusions into a shipping tube. (Black anodized parts actually weights more, due to the dye absorbed into the aluminum to turn it black).
2) We drop it per Fedex’s drop test specification – 10 drops at 30″ onto a steel plate. (We substituted concrete for a steel plate), open up the package to verify that the contents survived. Repack per step 1.
3) We then drop the packaging to failure to see what abuse it’ll take. Currently, our packaging survives 12 drops at a whopping 2.5meters (8 ft) onto asphalt. This is achieved by holding the tube arm’s length out and dropping it off a loading dock.
4) When the packaging fails we open it up and document any damages. Usually, the ends get dinged up a little bit but overall the extrusions are still usable.
5) We will then saw off the damaged portion of the extrusion and donate the material to FIRST robotics teams.
With regards to cutting the extrusion – we understand that not everyone wants a big chop saw that can potentially slice fingers off. We’ve been researching different methods of cutting the extrusions. Here’s a sneak peek at a 3D printable miter box that we are currently testing. It uses hardened steel pins, known as drill rods, for guiding the hack saw blade:
That’s it for this update! It’s been a long journey, and there’s light at the end of the tunnel – with at least a 2 sigma certainty that the light isn’t’ from a freight train…
-=- Terence, Rachel and the furry monster puppy
Please, share the files for miter box
… it will be a great thing to print with my new printrbot!
2012-July-17 at 02:19
Looking forward to receiving mine! Also, wanted to add a quick note regarding your update and final mesage about cutting. If in fact you are using drill rod, it is not hardened (unless you have done it yourself). On the other hand, dowel pins are already hardened but do cost more.
Keith
2012-July-17 at 06:32
Thanks! I’m considering (don’t laugh!) firing up the BBQ and doing my heat treatment on there with the air-hardening stuff. Also I can get tungsten carbide drill blanks, but they are pricy ($2.00 per 2″ piece).
-=- Terence
2012-July-17 at 10:06
Terence: Just received FedEx shipment to northeast Tennessee (on my “20K day” according to the metric calendar; Happy Birthday, me!). Tube and contents arrived in pristine condition (i.e., with only the slightest ding on the cardboard shipping tube end extending beyond the metal end cap…which doesn’t really count). The extrusions are beautifully engineered and anodized; no damage anywhere. All 1515 extrusions and ordered parts—plus a few extra goodies, Thanks!—were shipped as ordered (algebraically*). In short, I am a delighted first time customer & looking forward to making my first frame assembly for a scientific data collection project in anticipation of making a follow-up order soon. Thanks!
You have done this one correctly. Your planning & hard work have made this one of the very best Kickstarter campaigns I have participated in to date. Best wishes to you and the whole OpenBeam team for a long and fruitful operation. Holler when you do another Kickstarter campaign.
* 2 bags x 100 nuts/bag = 1 bag x 200 nuts/bag –> this threw me off at first
2012-July-18 at 13:57
Hi Terence,
Now that the OpenBeams are shipped. Will you be releasing the CAD files for the extrusions themselves? I noticed that you have already released the rest of the related parts’ CAD files except for the extrusions.
Thanks!
2012-July-18 at 23:43
I have not released the drawing files for the extrusion as it is under quotation right now in Guangdong, China for a second source to better serve our European and Pacific Rim customers. Once they have a good enough head start I’ll release it. Probably in a week or two.
2012-July-18 at 23:57
Add my vote for the miter box design- we could really use one here!
2012-July-21 at 11:32
Okay, we are printing the miterbox now. If successful I’ll blog it and release the .STL files. We’ve had a heck of a time trying to get the file to slice.
-=- Terence
2012-July-22 at 14:35
My OpenBeam arrived! Nice packaging!!! Is there an easy way to open / get the metal end off? I want to be able to keep the tube to store my parts.
2012-July-22 at 14:31
Yes – Whack the side of the tube with a hammer of a pair of Channel-Lock pliers. That will dent the cap. Now grab the dented edge with the pliers to twist and pull and it’ll crumble the cap in such a way that you’ll reduce the diameter on the cap. The cap will the slide right out.
I’ll probably video this later today, still have a pile of shipping paperwork for all my international orders to fill.
2012-July-22 at 14:37
http://www.youtube.com/watch?v=HAP0848o9mE Has the unbox/untubing
2012-July-23 at 17:20