Project Logs

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• A tedious task

  Daniel Nikolajsen • 06/15/2022 at 07:38 • 0 comments

  Production is taking me a lot of time. Especially the aluminum parts that I make from scratch, and then cut, drill, grind, sand-blast and paint. Its entertaining but extremely time consuming. 

  The new electric furnace has almost doubled my productivity but it still takes maaany hours to make a single unit. I will probably need to clock all the different tasks in the next batch, so I can see where the bottlenecks are. But most importantly, the quality is getting better and better as I learn more about the process and produce better original patterns like the one below. Its a sheet of MDF with a 3D-printed pattern, coated with spray filler and epoxy paint. One part takes two of these, one positive and one negative. That means I have a total of 10 different molds, almost every one I have needed to redesign at least once. So only creating the patterns has taken me over a month of hard work and several hundred dollars.

  The dream would be to just hire a firm to make die-cast parts instead of my sand-cast ones. But the setup fees for making the molds are insane and I'm not interested in taking an investor since its such a niche product and I have no idea how long I can be doing this. But hopefully I can make a few hundred units before I run out of juice.

  Whats most important is that the quality has gotten significantly better since the very first prototype almost 2 years ago, and I have a few improvements left but mostly regarding the software and the app. Hopefully all of you - my customers - enjoy the enormous effort I put into making them. It's far from mass-produced.

• Furnace MK2

  Daniel Nikolajsen • 06/05/2022 at 07:52 • 0 comments

  Well, if at first you don't succeed....

  The electric furnace that I built worked for some time, at least a few full days of foundry work. But the chamotte fire bricks took way too long to warm up, around 3 hours from turning it on until the aluminum was ready for pouring. 

  So I decided to replace the fire bricks with a more advanced insulating brick, which I got to test yesterday. And it made a huge difference! The furnace reached the correct temperature in only 20 minutes, and in an extra 15-20mins the aluminum is ready. 

  Also when I disassembled the furnace, I found that all the metal wire and parts that I had used to fasten the bricks and the kanthal-wire had gotten so oxidized that they just fell apart into powder. So now I replaced the cable joints with stainless ones, that hopefully will last a bit longer. Also the brick itself is insulating the furnace so the heat wont transfer out as much.
  

  Now hopefully I can finish the last parts for the current batch of Satrans. Wohoo!

• Up and running again

  Daniel Nikolajsen • 05/10/2022 at 07:38 • 0 comments

  Finally Im getting somewhere with the first proper production run. After the initial zero series I had a few weeks downtime when building the electric furnace and better matchplates for the casting process, but now its all hands on deck to get a new batch ready in a week or two. 

  Casting, drilling, grinding, blasting, painting. So much work, but way more fun than spending my time in an office...

• The heat is on

  Daniel Nikolajsen • 05/05/2022 at 20:05 • 0 comments

  Finally the furnace is working, reaching up to 800 celcius which is enough for melting aluminum. But I wish I used another kind of fire brick, because the chamotte-stones take a lot of energy to warm up. But I can replace them later. Now its time to produce some more Satrans... wohoo!

• Try, try again

  Daniel Nikolajsen • 05/04/2022 at 09:57 • 0 comments

  The first trial run of the electric smelting furnace did not work quite as I had hoped. After about an hour the heating element gave up. Apparently the connection between the kanthal-wire and the cable couldnt take the extreme heat.

  This time I twisted the end of the kanthal resistance wire into sort of a "litz wire", and connected the heat-resistant cable with bolts and spacers. Hopefully this will prevent most of the heat to travel from the kanthal to the cable. 

• I'm electric

  Daniel Nikolajsen • 04/27/2022 at 05:10 • 0 comments

  Its not only a song by a local band called Melody Club, but "I'm electric" also states that the amazing and time-saving electric foundry is getting closer to completion.

  I asked a good friend of mine to help me out in building a 2.1kW electric furnace instead of my currently horrendous wood-fired forge. Its a relatively easy setup but looks almost professional thanks to my friends excellent work.

  The inside has a ceramic blanket surrounding a pile of chamotte-stones and a 12 meter long kanthal-wire turned into a spiral to give a nice 25ohm resistance, which in theory should give us 2100watt. Slightly below what my 10A outlets can handle. The bottom of the furnace is an old circular pizza oven stone that fit nicely inside the big steel bin.

  I was up until late yesterday connecting all the wires, but for some reason the PID temperature controller didnt want to run on 12volt which the manual stated it would, so today I'll try 230vac instead and hope for better luck...

• Cope and drag

  Daniel Nikolajsen • 04/12/2022 at 09:36 • 0 comments

  The first batch of Satrans are on their way to the very first customers and I am working hard to speed up production so even more can enjoy the tech. 

  Sand casting has proven the greatest challenge which takes up a lot of production time. My first 3D-printed original patterns worked but were time-consuming and didnt last more than 10-20 uses. So this time I am trying something new - "cope and drag patterns". 

  This is a two-part original made out of MDF-board, 3D-printed parts, glue, spray filler and a few coats of heat-tolerant epoxy paint on top. When you cast a lot the petrobond sand will get quite hot and can damage the patterns, so epoxy should give some extra protection. If they hold up for 50 uses or more I would be happy, otherwise I need to step up the game even further with fiberglass-patterns. 
  

• Finalizing the first batch

  Daniel Nikolajsen • 03/27/2022 at 08:28 • 2 comments

  Finally Im getting close to finishing the first batch of Satrans. Hopefully I can sell the first ones in the week to come. 

  The new default paint job is grey like this prototype. But I will make them in other colors later, like black or olive green for those hiding out in the bush instead of mounting it on their rooftop, or just wants that extra "cool factor". 

  The rubber gasket on the side is for those who wants the antenna coax cable to run inside the mount pipe instead of hanging loose on the outside. Neat and tidy, just like IKEA.

  Visit www.satran.io and signup for the newsletter to make sure you get notified as soon as they hit the shelves. 

• I never get board

  Daniel Nikolajsen • 03/04/2022 at 08:07 • 0 comments

  But now I do! Yesterday the PCBs finally arrived after a long wait, and I hastily soldered together the very first one (the green one is the old prototype). Fingers crossed that it will work and that I didnt mess something up when I made last-minute design tweaks, but at least they look awesome with the logo and all.

• One down, 999 to go

  Daniel Nikolajsen • 03/03/2022 at 10:18 • 0 comments

  Yesterday I managed to make the very first sand cast sides for the rotator. Its enough to put together the very first all-metal prototype, but hundreds more are to come.

  The sides have very fine details and thin sections that are almost impossible to sand cast. Bigger companies use die casting for such things, but for that you'll need insanely expensive molds. But with lots of practice, a good alloy and "jävlar anamma" (meaning grit) as we call it in sweden, anything is possible.

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