1-1-25 - Production Progress

We are moving into production! Current work is within the Injection Molding phase below. Specifically, we’re finalizing the mold design spec to begin cutting the cavities. Follow our dev log on Bluesky for more detailed updates.

• Funds collected during this phase are immediately rolled forward into the Injection Molding and PCB Assembly pre-production phases.

Mold Cavity Fabrication

• The injection mold cavity is an assembly of solid steel about the size of a microwave, with Zero’s features carved precisely into its layers. ABS pellets are melted and injected into the cavity, allowed to cool, then ejected to make way for the next cycle.

Revisions

• After the first sample parts are shot, they are precisely measured and evaluated for fit and finish. Any required changes are performed on the cavity tooling before production sign-off.

Production Run

• Zero’s custom mold tooling is loaded into a room-sized machine…a bunch of hissing and clanging happens…then Zero’s knobs and fader caps tumble out onto a conveyer belt. After the parts cool, further post-processing steps secure the pushbuttons inside the face of Zero’s enclosure. A 1000-piece production run takes 2-3 weeks.

Pre-Compliance Testing

• Zero’s circuit board is tested and certified for compliance with regulatory standards. Any required changes are performed and follow-up testing verifies the results.

Pre-Production Prototype

• A final round of production test articles is fabricated. These circuit boards represent the design which will ship inside Zero, and will give us a final QA pass before ordering a full run.

QA

• Zero’s circuit board is tested for full functionality and the assembly process is finalized.

Production Run

• Parts are ordered from distributors, FR4 fiberglass and copper foil are laminated together, and circuit traces are etched. A machine then deposits Zero’s hundreds of electrical components precisely into place. Finally the entire assembly moves through an infrared oven along a conveyer belt, melting the solder to form the final electrical inter-connections.

Software Installation

• Zero’s system software is flashed onto the circuit boards and a round of QA tests are run to verify the knobs, faders, screen, and I/O ports function as designed.

Device Assembly & Shipping

• Everything is bolted into place, bagged up, stuffed into the shipping box, and mailed out.