We got samples out of the molds for the horn and button and they were almost perfect. Getting these is a huge step towards production as it is by far the riskiest and most complicated part of the process (once you get past design). I know many of you are anxious to hear if the horns will come before the weather gets warmer; I still don’t have an accurate estimate but I really really appreciate everyone positivity and patience. As the riskiest part of development is almost over expect to have a fairly accurate estimate within a month.
In this picture you can see the water-resistant connector for the button reaching out of the screen. Near the base of the connector you see the two holes which make the charging indicator lights visible; these holes will be filled with clear glue to make them water resistant.
The button! You can see the velcro strap now, and the logo in the center to give a tactile feel (much more accurate than it was with the 3D printed versions). In previous updates I’ve suggested that the the center of this button would be colored “Loud Bicycle Orange” but I’ve been advised to make it black instead. Do any of you feel strongly (or weakly) about the color of button? Specifically the part that is white/clear in the photo below.
Another photo of the strap – allowing you to attach it anywhere and remove it quickly if you choose to.
We designed the circuit board with the assumption that the material would be able to flex a little. The material they selected has some fiber inside which makes it super strong – but with the additional rigidity the circuit board (PCB) didn’t fit. The overseas team made a quick change to the PCB so it fits again. In this photo you can also see the little metal threads inside the holes which are going to let you take the horn on and off without wearing down the plastic.
In this side photo you can see the foam gasket material sandwiched between the top and bottom of the case, sealing off the sensitive electronics from the potentially wet outdoors.
There was a problem on the right side though; the circle in the photo below points to where top and bottom of the housing do not align. This is because there was as small amount of asymmetry between the left and right sides which caused the bottom right side to shrink a bit. The arrow points to where they will add ribs to help prevent the shrinkage and get things in alignment.
Thanks for reading!
That's all for now, glad to hear your comments as always – but this time especially about the color of the button.