Our manufacturer has had a number of highly unusual problems that interrupted production, as well as some of the more expected problems making a new product. The good news is that they're worked out, and they've been cranking away. The bad news is that means we didn't get them all shipped out last week. However, the majority of them are being driven the 102 miles from the manufacturer to me right now, and we will ship them today. Hopefully, the rest will go out through the week, although we don't know the daily yields from production yet. I'll keep you posted. Apologies for the delay!
If you're curious, I've listed out what these manufacturing problems look like below.
1) Mr.Ghost was inconsistently warping as it cooled coming out of the mold. The core stays molten from the plastic injection, but the outside doesn't. Because the product cools unevenly, it will warp to one side or the other.
- Corrected by having to mill cooling jigs for Mr.Ghost to hold it straight while cooling.
2) Mr.Ghost looked like it was running fine, but on testing, the electronics were failing at a high rate (after previous batches had been fine). After quite some investigation (by cutting open Mr.Ghost), the manufacturer found that one of the main solder joints was breaking.
- Corrected by re-soldering all of the electronics with a higher surface area method.
3) Mr.Ghost now looked great, and the electronics were testing with very high success rates. Ran a large batch. Instead of testing using the test equipment, plugged it into an iPhone and...wait...it didn't fit into the iPhone. The new soldering method had slightly melted the insulator ring in 75% of the produced units so that it couldn't fit in an iPhone anymore.
- Corrected by throwing out bad units, and changing the soldering process to conduct less heat to the TRRS connector.
4) Which brings us here! Good looking units that work great, but require a little extra TLC to make.