First Ever Roost from the Production Tools
In this update:
- Finalize your Pledges and Add-ons now. (Still OK to change shipping address later)
- First Ever Production Roost!
- Updated Production Plan
- Updated Shipping Date
Finalize your Pledges and Add-Ons now (in BackerKit)
We need final counts for Roost production. You have 1 week to make any final changes to the quantity of Roosts / RKM Cases you want shipped. You WILL still be able to update your shipping address after this point.
For only those that have added additional Roosts / RKM Cases, you will be charged for these at this point. These charges come from Backerkit. If you have not added anything to your pledge, there will be no charges.
First Ever Roost from Production Molds!
You never really know what injection molded parts will be shaped like and look like until you've molded them for the first time, it's the nature of the beast. It's a very tense experience putting together the first version.
And I'm extremely excited to report that this new Roost is going to be an absolute winner! This first run of the parts on the tools produces a Roost that is almost ship-able, the whole team was extremely proud and excited with this result. Here is Video of first ever Roost from Production Tooling in action, it's serial number E001 (E for 'Engineering'):
The less great news is that we have a couple of small issues with precision fits and matching one molded part to another. One of the issues requires re-machining some small components of a mold and will take 3 weeks to machine and retest. Which is a direct hit to the schedule.
After this work is completed, we will "texture" the molds. And then do one final full run of engineering parts at the injection mold builder. These we expect these to build a perfect Roost.
The molds (7,000lbs+ of them) then get shipped over to the mass manufacturer for production use. We expect to have the injection molds getting trialed at the manufacturer by the first week in November.
Updated Production Plan
The Roost is really one giant moving part with lots of precision fits. After careful consideration with the manufacturer, we've decided to do a "Short Run" of Roosts before we do the big run of 15,000+. What we really really don't want happening is making 30,000+ of a single part (each Roost requires 2 of same part) only to find out that it doesn't fit. That would hit delivery by many weeks and waste lots of material.
The reason this can happen is that even through we've already made a perfect Roost on the tools at the Injection Mold builder, they have different injection molding processes and "presses" (the machines that squirt the plastic thru the molds) than what the mass manufacturer uses. Very subtle differences in process parameters (injection molding pressures, temperatures, dwell times, many, many more) can cause very real changes in the final parts.
Doing this precautionary "Short Run" of Roosts will add another 2 weeks to the schedule.
And finally, once mass manufacturing starts rolling, the first Roosts will be ready to ship within 2 weeks and it will take 5 weeks total to complete all Kickstarter Roosts. We will be shipping continuously over this period, in the order of your pledge date.
(The BIG caveat here is if the "Short Run" is trending perfectly, we will just continue running the machines for the full production run of 15,000+. This is what every one is hoping for, but we are now planning for the slower start).
Updated Shipping Date
So, the bad news, with the above delays, shipping will begin in mid December and run through mid January. (We lose some time over holiday shutdowns).
This is obviously a big hit, which I am truly sorry for, I want to get these Roosts under your laptops as much as you want them there. The good news is that the major risks are behind us and we will absolutely will be shipping an amazing final product, there is zero question about that. All parties involved, from suppliers to manufacturers, are committed to the above plan.
(For "Will my Roost ship in time for holidays?", please hold on to that question for now. Once we have completed the "Short Run" in late November, we will know much more accurately when your ship date will be).
Thank you again,
Next update will be post the tool modifications, with production-ready Roosts in hand.