When new chassis arrive, the Taiko team doesn’t know what to expect - success rates can range from 0% to 100%. Fortunately, Emile personally inspected this upcoming batch and it looked like a full pass, so unless there’s damage during shipping or handling, we expect to have sufficient quantity next week.
Let me elaborate on this a bit more in depth.
Transportation damage aside, the powder coating yield has indeed been 100%.
This is not standard powder coating though.
In Europe we have a rating system of 6-10 for decorative finishing. Powder coating is usually grade 6, as for example applied on wheel rims, household items etc, anything which needs to look decent to good and requires a durable finish.
Decorative anodising can reach a 8-9 rating, highly depending on the type of aluminium alloy used, and pre-finishing, brushed and then anodised aluminium can be an 8, bead blasted then anodised can reach a 9 rating. On the Olympus we can actually never reach that 9 rating due to the physical size which in turn requires manual labour to finish, it can never be 100% consistent. We have one anodiser which can reach about a 8.5 rating on the Olympus, which does look really great.
The coating company we found recently can apply a powder coating finish at quality level 10. It’s basically flawless. This is rare, there just aren’t many companies doing this as it’s just much more profitable to fill your factory with level 6 lines, and you can get a level 10 finish with other types of coating, which however are not as durable and/or fragile (spray painting) or not suitable for, again, the object size.
So what we have is a coating, with similar durability to anodising, at the same (actually higher) quality level, with no process induced rejection rates.
What is the problem, well it does not look 100% like anodised, and you all have ordered anodised. Even though everyone who has seen it thus far prefers it over anodised, it’s not 100% the same. It’s a deeper black with slightly more surface texture and it reflects light just a bit more. It looks more “luxurious”. The other problem is, although we got black down now, it will take time to get silver right. There is no coating available which matches anodised silver within say 90%. This means we need to have a coating custom made, this takes a month, if an adjustment is necessary, another month. We’re at that “another month”.
What it means for you who have an Olympus on order is that you can choose between coating and anodised.
For NEW Olympus orders in black, we will ONLY supply black coated, anodised will not be an option.
For NEW Olympus orders in silver, we will accept anodised only until we have silver coating ready.
We will build up a stock of anodised chassis parts and I/Os to match your anodised Olympus if you need a chassis parts replaced or if you want to add an I/O to your Olympus.
But we are unfortunately seeing ourselves forced to abandoning anodising otherwise, we cannot produce the quantities required, and the process is just too wasteful.
First of all to have any sort of reasonable yield on the 6 chassis a week the only anodiser in Western Europe (yes we’ve approached them all) can or is willing to finish, we can only use the outter 1/6th of the raw aluminium ingots. This is likely to get even worse over time, by 2050 all aluminium will be 50/50 new/recycled, and this is a good example as the other 5/6th of the ingots can go straight to recycling.
Then we have CNC machining, 6 hours for an Olympus bottom, 4 hours for a top, 8 hours for an I/O.
Sanding / polishing, 1 hour each chassis part.
Then the bead-blasting and anodising, 4 hours each chassis part.
Re-anodising, 6 hours each part, we gave up on that as when our supplier needs to re-anodise they can only manage 4 chassis a week.
This means if we have to reject a chassis, we have wasted 20 hours of labour. Add an I/O and it’s 33 hours. On top of that we’ve added a 6ft tall tower of aluminium blocks with a 20*20” footprint to recycling.
If we stick to our current process, we’d be forced to double our prices, at least. An increase is unavoidable, but I’d like to keep this somewhat manageable, therefor we have no other choice than to switch to offering coating options exclusively for new orders.