One of the most interesting parts about the whole process of making an iPhone case that fits standard 'bricks' is how difficult of a problem it is to make something as simple but accurate as an ordinary brick. The tolerances are tighter than
you might imagine.
Though we had laser-scanned real bricks, that wasn't close enough, given the various things that happen to plastic parts during the molding process. We literally had to 'grow' the mold, a tiny step at a time, until we got the 'fit' that we desired.
Though we had laser-scanned real bricks, that wasn't close enough, given the various things that happen to plastic parts during the molding process. We literally had to 'grow' the mold, a tiny step at a time, until we got the 'fit' that we desired.
Nor was 'size' the only problem.
The photo here is of a very early pre-production part. The cloudiness you see below is not present in the real parts. We solved this particular problem by a combination of a slight materials change and a change to the pressure used during the molding process. Just another problem we had to solve on the way toward brick mastery!
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