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A tedious task

A project log for SATRAN - Satellite Tracking Antenna

Wifi-controlled, azimuth/elevation antenna rotator.

daniel-nikolajsenDaniel Nikolajsen 06/15/2022 at 07:380 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.

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