## Process - Form the wire 1. Cut wire to 20mm 2. Bend wire in half to proper angle, with bend in middle of wire - Weld the wire to the base - Position the wire - Be able to flip the jig over to weld from both sides ## Forming the wire by hand ### Cutting to length - Setting length - ![[Pasted image 20230121145515.png|lg]] - Marking Length - I pushed down on the wire on the caliper jaws to put a slight bend in the wire at 20 mm - ![[Pasted image 20230121145643.png|lg]] - Cutting - When I went to cut the wire at the bend I ended up cutting the wire ~1-2 mm short - Could probably do better by hand still, but would like to figure out something more [[poke yoke]] ### Folding in half - I set the calipers to 10mm, then slid the wire up against the opposing jaw. - Then, like when marking the cut I pushed down on the edge of the calipers, forming the bend seen in the picture - ![[Pasted image 20230121150149.png|lg]] - To get the bend tighter, I grabbed both of the sides of the loop, one in each and, and moved them closer together, approximating the angle by eye. - ![[Pasted image 20230121150552.png|lg]] - ### Welding - Printed a little jig to hold the base horizontally - Measured filament height with calipers (13.43mm) and marked out on a piece of tape ![[1DCE70DA-AB80-44A6-954B-B684209D403D_1_105_c.jpeg|lg]] - Used tweezers in micromanipulator to line up the bent filament with the posts by eye so that the tip is both 1) even with the line and 2) centered between the posts - Released filament, flipped it 180°, put it back in the jig ## Jig Ideas - Using a [[Wehnelt]] to hold the base as an alignment jig - This would make getting the dimensions on depth right pretty easy, but would not support the ceramic posts in the way that a fabricated jig would. ## Dimensions - Each leg of the bent wire looks to be 10 mm long, making the overall wire length 20 mm (or very close this is by eye with calipers) ## What we are noticing trying a few welds - As you apply pressure with the weld head, the slop in the z axis travel of the weld head causes the electrodes to want to shift a bit - This makes welding the wire completely parallel to the post more challenging ## DOF Notes ![[New Drawing 2 1.png]] ## Weld Electrode Positon ![[New Drawing.png]] ## Filament and Wenhelt construction ![[0C075E2F-B223-4AED-9FE1-878D9A657765.jpeg]] ## Comparing with [[K-Type Filament]] ![[D7121258-2E90-4087-8AE1-AC81AF2DF9C3.jpeg]]