Case Study

Complete Product Development

A Projection Machine having Computing Capabilities

Building on a
Concept

In 2007 one of our clients, a projector

manufacturer, approached us with the vision to
build a projection device with computing
capabilities or a computing device with
projection capabilities. Either way nothing like that
existed in the market, for us to get a working idea
of the equipment or do reverse engineering on
some part. We understood the concept and build
equipment that is part projector & part computer.
It is named Magic Studio and is selling in the
Indian market as of today. Very soon the client is
planning to take it to the international market.

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Block Diagram lay out of Magic Studio

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Normal 220 V, 5 A AC In from wall outlet;

Spring return type Power-on switch for make &
break type operation;
Conditioned DC power supply of 5V, 12V, G
from SMPS to Processing Unit;
Conditioned DC power supply 5V, G from SMPS
to TV Tuner;
Conditioned DC power supply 5V, 12V, G from
SMPS to Projection engine;
Conditioned DC power supply 6V, 12V, G from
SMPS to Amplification Unit;
VGA-out from Processing Unit to Projection Unit
video-in port 1;
RS 232 connection between the processing unit
& the projection engine for managing the later
from the former;
Connection between the TV Tuner unit & the
processing unit carrying power from the
processing unit to the TV Tuner unit,
Audio/Video feed from the Tuner unit to the
processing unit, control signals from the
processing unit to the Tuner unit;
Line level audio generated by the processing
unit sent to Amplifier;
Output of the video scalar cum switcher to the
projection engine;
Video-in from any external playback device
like camcorder/VHS/VCD/DVD to the video
scalar cum switcher unit;
VGA-in from any external computer or
document camera to the video scalar cum
switcher unit;
LAN connection to processing unit;
Four USB 2.0 connections to the processing unit
for connecting external storage devices like
pen drives and the receiver of the wireless
keyboard & mouse;
RF connection to the TV Tuner unit for watching
of cable television;
Audio-in to pre-amplifier & then to amplifier
(RCA x 2);
Line-Out from Amplifier (RCA X 2);

PRODUCT CONCEPT
(DESIGN & ENGINEERING)
In the process of generation of product concept,
the concept of the Magic Studio was developed
keeping in mind the following issues:

Wood Patterns
Mock up

HAND SKETCHING-THE
PRIMARY STEP TOWARDS
DEVELOPMENT FROM A
CONCEPT

To give the client a look and feel of how the

finished machine might look like, this process
involves cutting of wood with the utility of CNC
machining into the product shape. Wood patterns
were cut to view the overall appearance and
check the working of some basic gauges. This
helped save the repeated cost of prototypes and
ensured a mechanically true design

Number of standard components

Fitment with the now defined child parts
Minimum number of components
Reduce cost of mold
Planning for future accessories/up
gradations

Assembly consideration with the

following points

Detailed assembly drawing

Cross check solid interference
Child parts nesting and mounting
Model validation of individual component by means of
product life and mold manufacturing
Maintaining weight and wall thickness of individual
components
Molding cost (Approximately as subjected to tool design)
Material cost, etc.

We produced the dimensional detailed drawings to freeze dimensions

along with appropriate tolerance, which improves the quality of the
product while manufacturing.

Prototyping

After the client was satisfied with the shape of the product from the
wood pattern and the dimensions were found ok from the 3D
model, we made a prototype of the equipment to cross check the
actual fitment of various child parts. Prototypes are necessarily
made from transparent plastic to facilitate the crosschecking of
child parts before & after fitment. Below are some photographs with
the fitment checking in progress:

Tool Design

Molds Manufacturing

Amongst other things, tool design involves

the selection of the material composition,
issues like heat resistance of various
materials, their typical shrinkage after
cooling, the mold flow, the finish of the
material after it exits the mold etc. are to
be considered. There can be a mixture of
various types of material that goes into the
making of the final product body, as
happened in this case. Part of the product
was molded in PC and part in ABS,
transparent parts like the remote IR sensor
windows were molded from SAN. Below
are some diagrams of the tool design.

For the tool Manufacturing, JIG has partners

in Shenzhen, who are proficient in their own
rights and who have been finalized by JIG
after visiting their tool rooms, inspecting them
in action, understanding their capabilities &
infrastructure. Finally, their understanding of
concepts towards job allocation. We have
also inspected their end products to
understand their esthetics in terms of
designing parting lines, flow marks that relate
to rejection of molding. Below are some
photographs of the tool designed for our
client for this product.