Finishing

 The button housing was sent to 3d printing (Rapid Prototyping) which took approximately one and a half hours, after which the housing was placed into the tank to remove the excess scaffolding which is shown below in brown. Rapid Prototyping in this scenario was fused deposition modelling in ABS plasctic. Its a process which allows parts to be made by building them up layer by layer in ABS plastic. This can be an expensive process as 1cm cubed costs approximately 40p.  The manufacturing of this product cost approximately £5.00.

Once the scaffolding had been removed the button was tested in the slot to ensure a snug fit and the housing was sanded until a smooth finish was achieved.

Once the desired finish had been achieved the product was then brought t the spray booth where a coat of plastic primer was sprayed and left to dry. The next step in the finishing of the button housing was to pressure pot prime the button housing and ensure that even coats were being sprayed by sanding back any defects in the Primer. The photo below depicts the button housing in Pressure pot primer.

 While the button housing was left to dry between coats of Plastic Primer and Pressure Pot Primer some Sanding Sealer was applied to the Speaker Shells. One coat of Sanding Sealer to begin, which was sanded back with Flour Paper in order to achieve a smooth finish and this process was again repeated before applying a coat of clear Briwax with a fine grade wire wool. The Briwax was then left to dry before applying a second coat.

While the Briwax was drying the button housing could then receive its first coat of matte black spray. The housing would then be left to dry for approximately four hours before the second coat was applied. This was coat was then left overnight.

The next task was to glue the speakers into the speaker housing (in white below) and also to glue the finials (Black disks) above the speaker.

A 12v 1000ma plug was purchased to power to the speakers which was then PAC tested as a safety precaution. The DC end would then be cut off to connect it to the circuit board of the speakers.

 The speaker lead connects to the circuit board through the button housing as does the power lead. While the speaker leads are housed internally in the speaker shell. All components have been soldered onto the circuit bored using lead free soldering wire.