This final development update shows a few lessons learned in trying to streamline the assembly process.

Two custom brass soldering tips were machined to help improve the design of the standoffs. The first one is a 90° holder for threaded heat-set inserts, as the standard straight tips would interfere with plastic components during installation. This produces a much more professional look compared to machine screw threads that can easily strip in plastic components.

The second custom soldering iron tip came about from wanting an alternative way to mount the case fans. This tip has a concave recess that, when heated and pressed against a plastic post, creates a dome-shaped cap and captures the fan in place. Definitely a more economical solution that replaces the 4 screws used before.

One last helpful tool was made to improve the manual soldering that needs to be done after receiving the custom boards, which are only populated with SMT components. This 3D printed fixture acts as a holder for the through-hole components. The PCBs are then placed onto shelves with alignment pins which elevate them to the exact height and orientation for soldering.