Vacuum forming is one of those things that are simple in theory, but difficult in practice. It's like what they say about bread-making. Everybody can make bread, but few people can make great bread. It's deceptively simple. My goal was to make it just plain simple.
The production was going great. We had a proven design. We worked closely with our suppliers to get every detail of every component just right. Here we're taking about dozens of custom parts. Indeed most of the KS funds went to tooling.
From the early samples we built prototype units that reflected our design. Time check, it was looking like we'll ship BEFORE October. All we had to do was wait for the parts to arrive and we can begin assembly.
Fabricating a few parts is one thing. Making a few hundred is a different breast. And few our suppliers were dogged by this fact. Some of the metal parts had to be sent back, the early injection molded enclosure had a warp that took the tooling engineers forever to fix. It was like that. That comfortable lead that we had began to shrink. Good thing we had that buffer at all. We could still ship on time, no worries.
It was in early October that I had that feeling in the gut. We might not make it. I hopped on a plane. I pushed my tardy suppliers to deliver. And to their credit each one was professional and they hustled. But the thing that would ultimately cause the delay was the PCB. One of the earliest things on our stock shelves. It was like being drenched in icy water.
So that's what we've been trying to fix these past weeks. The good news is it's fixed. And we've already received a few boards. We had to negotiate for some production time with our PCB manufacturer during their busiest time of year. That they could eke out a small batch of boards at all is a miracle.
Even better news it's enough to begin shipping, starting with our Early Birds then down the backlog as we receive the boards in batches.
The coast is looking clear here on out. By March we expect to get ahead of the demand so no one will ever have to wait for their Vaquform and we could forget this dark period in Vaquform history ever handled! Haha!
Thanks for your patience everyone. Expect tracking numbers real soon!