Product Development

As I mentioned last week, I’m using the wait for the Triple-O knife to do some redesign work.  Here’s a picture of a pre-production prototype for the new sheath.  As you can see, in addition to vertical and horizontal mounting … Continued

In Part 13 of my series on the Making of the Wall-Saver safety cylinder I discussed what I thought was the final process for manufacture and assembly—and a serious problem. Less than 10% of plastic inserts were coming back out … Continued

In Part 12 of my series on the making of the Wall-Saver safety cylinder, I discussed the mistake I made in plastic insert design and the correction of reducing the size of the retaning ridge. So…now I had 7 good … Continued

In Part 11 of my series on the making of the Wall-Saver safety cylinder, I discussed the making of the plastic inserts that hold the brass plungers in place. Having figured out how to make them reliably, there remained the … Continued

In Part 10 of my series on the making of the Wall-Saver safety cylinder, I talked about how I finally arrived at a successful production method for the main cylinder body. But as I had mentioned in part 5, there … Continued

In Part 9 of my series on the making of the Wall-Saver safety cylinder, I discussed solving one set of problems, only to uncover another: molds that had weird angles resulting in off-center holes. Given the tolerances built into modern … Continued

In Part 8 of my series on the making of the Wall-Saver safety cylinder, I talked about how I solved (accidentally) several issues with getting cylinders made efficiently. But what I didn’t talk about was how the solution, for reasons … Continued

In Part 7 of my series on the making of the Wall-Saver safety cylinder, I discussed how I overcame shrinkage problems, but immediately ran into difficulty with the dimensionally-excellent mold I had made from it. The big one—getting a complete … Continued