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Thanks a lot! This is a great guide. One more question, if I may: I am considering a small hardware business (so far I am in the process of building the protot

Thanks a lot! This is a great guide. One more question, if I may: I am considering a small hardware business (so far I am in the process of building the prototype for my own use). My project has to fit a wide assortment of differently-shaped phones. Also, as it's a niche product aimed at a hobbyist market and not of massive appeal like the Glif (http://www.kickstarter.com/projects/danprovost/glif-iphone-4-tripod-mount-and-stand/ http://www.kickstarter.com/projects/danprovost/glif-iphone-4...), I will need to make rather small runs for each phone. I am thinking of building it in two pieces: the actual electronics (a bigger run, because it will be shared by all phone models) and a foam housing made to measure for each phone model. The electronics will be the same for all phone models, and will go into the foam shell. Then the foam shell will clip on/around the phone. ¿How would you fabricate small runs of shapes made of high-density foam?

curt 16y ago
I've never used foam before but I do know the material and they can't be prototyped the same way plastic parts can. What you're going to have to likely do is have them milled which will raise the cost considerable. Look for a local shop in your area, they are all over the place. If you don't have a time constraint you should be able to negotiate a lower price. When you say 'small run' how many units? Part size? How many variations. If the quantity is large enough you can have an single mold produced with each part variation. While you will have extras it'll drastically drop the per unit cost. Most of the cost is the mold and setup (fixed costs), the materials cost next to nothing (couple dollars/pound).
- candeira 16y ago
  Part size: think about the same total volume of foam that an iPhone or an Android phone have. The size envelope is like two stacked pack of cigarrettes (obviously there are holes for the electronics and for the phones to be stuck in). I don't know the number of units or of variations yet. Once I have a working prototype and software my plan is to start a project in my local Kickstarter-alike which would tell me how many to make and, just as importantly, for how many different models of phones. Oh, and right now I am building the prototype the old way, with sheets of the material, x-acto and glue. CAD/CAM software and milled prototypes won't come into play until I have something that works. Then I will start trying to price the production. Right now I was just taking advantage of your offer to share your experience. Thanks again.

curt 16y ago

I've never used foam before but I do know the material and they can't be prototyped the same way plastic parts can. What you're going to have to likely do is have them milled which will raise the cost considerable. Look for a local shop in your area, they are all over the place. If you don't have a time constraint you should be able to negotiate a lower price. When you say 'small run' how many units? Part size? How many variations. If the quantity is large enough you can have an single mold produced with each part variation. While you will have extras it'll drastically drop the per unit cost. Most of the cost is the mold and setup (fixed costs), the materials cost next to nothing (couple dollars/pound).

candeira 16y ago
Part size: think about the same total volume of foam that an iPhone or an Android phone have. The size envelope is like two stacked pack of cigarrettes (obviously there are holes for the electronics and for the phones to be stuck in). I don't know the number of units or of variations yet. Once I have a working prototype and software my plan is to start a project in my local Kickstarter-alike which would tell me how many to make and, just as importantly, for how many different models of phones. Oh, and right now I am building the prototype the old way, with sheets of the material, x-acto and glue. CAD/CAM software and milled prototypes won't come into play until I have something that works. Then I will start trying to price the production. Right now I was just taking advantage of your offer to share your experience. Thanks again.