Surj

For my study of Industrial Design and Engineering I was looking for info on embedded systems and Gumstix-like projects. I found both your blogs greatly amusing, and found lots of great information. I also read you both look up to the physical engineering part of the project.

Since you indirectly helped me, I thought I’d give you some info on production of (plastic)products in really small batches (1-5 pcs).

There a several production techniques possible for a custom designed phone housing. You could, for instance just mill the whole thing out of – for example – aluminium. This would be quite costly, and not get the surface finish and geometry you are looking for.

In the world of rapid prototyping there are 2 main techniques: FDM and SLS. I think, for what you are doing, SLS is the most appropriate. The freedom of geometry is very high, the materials are relatively strong, and the production costs for a front- and backside are about $100.

As for the design part of the job, I find SolidWorks a really good choice.

I believe you’re both still in the phase of putting all the electronics together, so when the time is right, I’ll be more than happy to give you more info, if needed.

Best regards,