When we decided to start R&D on a new way to inspect films, we gave ourselves a blank slate. All we knew for certain was that we would take advantage of the latest technology including computer vision, computer controlled motors and transport, and the latest in materials science.
One of our pivotal choices was whether or not to use 3D printing 🖨️. There are pros and cons. Traditional methods for making metal and plastic parts are very precise. Precision is a good thing. 3D printers have a head that moves in four dimensions, melted plastic that comes out of it, and a platter to hold that plastic as it hardens, and that platter slowly moves as the plastic grows. It can’t be as precise as a laser cutter, as you might well imagine.
But speed matters too. Mostly in experimentation and trying out new ideas to make something work just a little bit better. So we chose 3D printing for some of the elements on the outside surface of the FI-16, things that we could continually improve and mail out to our customers.
If a film inspection station holds the film horizontal or nearly horizontal – FI-16 is about 15° off of horizontal and that’s enough to give a small amount of vertical force – then that raises the question of whether or not the film needs a platter on both sides. Gravity holds it down to one platter. So do you need a top platter?
Well the answer turns out to be – sometimes. Archival films do what they want. They don’t obey orders. So, does the top platter need to be the same as the bottom platter? The answer turns out to be – Yes or no. Sometimes.
So we ship an FI-16 with three bottom platters because the third one can be a top platter on the take-up reel if you need it. You rarely do but when you do, it’s just the thing. Then we kept experimenting with different kinds of top platters using our 3D printer.
Some of them are just like the bottom platter but made of plastic and therefore lighter. Easier to handle. Cheap to replace if you break it. Some of them have a gradual curve on the side that faces the film because the take-up reel film may want gentle nudging in the beginning and then not need it anymore after the film gets going. We call that one the UFO!
Then came the propeller.
Sometimes you want to nudge or wind the film by hand. You want to rotate the film on its platter and you want to see it while you do. So we started cutting away more and more of the UFO until it was just two straight bars in either direction. Then one of our film inspection operators said it was finicky to place her fingers on the thin plastic. Rather than make a thick chunk of plastic, we curved one edge of the bar upwards. Then we curved it upwards more. Now she can get a really good grip and she can see all of the film. And it still does its job as a top platter to keep the film winding nicely.
When we took it off the FI-16 and looked at it by itself, I swear it looks like – a propeller. With the spindle hole in the center it looks like you could stick it on your model airplane and send it off in the sky.
Printers, propellers, and platters, oh my! Hey, have a little fun while you work.