Wiardgroup

At 09:17 PM 3/14/2007, you wrote:

>If the public could change their perception of how a synthesizer 
>module must be
>constructed, we could have a renaisance unlike anything in the past.
>
>The single most expensive component in a synthesizer is the aluminum 
>faceplate.
>
>There is only one source for turnkey faceplaces in the US and they 
>are obscenely
>expensive. I pay $70 each for 1200 series faceplates.
>
>Your only other option involves using 4 different vendors. One to 
>get the metal blanks,
>one to put the holes in them, another to anodize them and another 
>yet to silkscreen them.
>Each step is a chance for errors to creep in. Also, there are 5 
>shipping charges to move
>everything from place to place or lose the whole batch. Or drop the box...
>
>The people who make printed circuit boards are used to doing most of 
>these operations to
>a higher degree of precision and more quickly and cheaply than 
>machine shops. If the
>buying public was willing to accept faceplates made from fiberglass 
>instead of metal, it
>would open the floodgates to new module designs.
>
>You can hardly see the difference either, the fiberglass is painted 
>and silkscreened just like
>the metal. Plus fiberglass is lighter and stiffer.
>
>I have heard this idea repeatedly from many people, but no one 
>believes people will buy
>modules with fiberglass faceplates. It is not historical.
>
>There are also design advantages to PC material faceplates. The 
>faceplate can become part
>of the circuit. Touch switches for triggers or mode selects are 
>essentially free. Things that
>are expensive in metal, like slots for linear pots or perforated 
>grills for speakers, now cost
>a few pennies instead of a few dollars.
>
>It is a practical idea, but the world is not yet ready for it.
>

Grant,

I really like the circuit board panel idea. The board shop I use even 
does black epoxy solder mask which would be fine for finish.
Although they can be a bit blotchy at times and getting a consistent 
result could be a problem.
Silk screening the text and graphics would be a snap. Board material 
also comes in thicknesses above 0.062"
for added rigidity. Having built in tracks for pots and jacks would 
be cool but they would have to be SMT so as not to poke through.
I am experimenting with a new panel making shop Metal Photo of Cincinatti.
They will anodize, machine and punch all holes using CNC equipment.
Price of my A series panels is about $12 each in sets of 10 panels.

Compared to the way I used to do it which was to have panels anodized 
and then machine and drill them myself this is a real boon.
I haven't received my first order yet but it sounds promising.

For my B series panels , they are laser cut aluminum with bent 
returns for rigidity which is extremely accurate and reasonable cost.
Tolerances are +/-.005" or better.
About $12 each in batches of 10.
I have them baked enamel finished by another shop ($3.00 each) but 
the laser sheet metal shop can arrange to have them anodized for 
about $200 for a lot of 100
I then silk screen them myself as I have not found a local screen 
shop that can provide consistent results. For some reason they have trouble
with registration of graphics with holes. Even the guys who claim to 
specialize in instrument panels....weird, don't know how they stay in business.

Perhaps the circuit board idea could be offered as a down and dirty 
cheaper option but then again the cost of panels isn't that
high compared to the overall cost of a module and a pcb version is 
only going to save about $10 compared to the methods I use.
The PCB panel is still going to cost $15-20 each in small runs.

Bruce