# S2 E4: Scaling up Manufacturing with Scott Miller

- Show: [The Builder Circle](https://hardwarepodcasts.com/podcast/the-builder-circle)
- Published: 2024-01-09
- Length: 55m
- Page: https://hardwarepodcasts.com/podcast/the-builder-circle/2024-01-09-s2-e4-scaling-up-manufacturing-with-scott-miller
- Listen: https://rss.com/podcasts/thebuildercircle/1293207

## Summary

Scott Miller, a hardware veteran with experience at iRobot, explains the strategic progression of manufacturing techniques, specifically focusing on the transition to injection molding. He details the economic crossover points, design for manufacturability (DFM) rules like draft angles and wall thickness, and the importance of engaging tooling shops early. The discussion covers various scaling methods including CNC, rubber molding, and other processes like die casting and rotomolding, while highlighting specific failure modes such as static discharge in the Roomba.

## Outline

1. Introduction: Scott Miller and the Manufacturing Transition
2. The Progression from 3D Printing to Injection Molding
3. Economics and Unit Count Crossover Points
4. Design for Manufacturability: Draft, Walls, and Undercuts
5. Engaging Tooling Shops and Moldflow Analysis
6. Alternative Mass Production Techniques: Die Casting, Blow Molding, and Rotomolding
7. Hardware Horror Stories: Roomba Tooling and Static Discharge
8. Design for Assembly: Ultrasonic Welding and Part Count Reduction

## Topics

- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Scaling production](https://hardwarepodcasts.com/topic/scaling-production)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Debugging & failure analysis](https://hardwarepodcasts.com/topic/debugging-and-failure-analysis)
- [Pricing, margins & unit economics](https://hardwarepodcasts.com/topic/pricing-and-unit-economics)

## Most relevant to

companies scaling up

## Mentioned

- iRobot (company)
- Roomba (product)
- Moldflow (tool)
- Proto Labs (company)
- Boothroyd Dewhurst (company)

## Related episodes from other shows

- [Transition from Prototype to Mass Manufacturing with Scott Miller of Dragon Innovation](https://hardwarepodcasts.com/podcast/predictable-designs-podcast/2020-03-12-transition-from-prototype-to-mass-manufacturing-with-scott-miller-of-dragon-inno) (Predictable Designs Podcast)
- [#032 - Why manufacturing in USA vs China is becoming interesting, with Scott N. Miller of Dragon Innovation, USA](https://hardwarepodcasts.com/podcast/the-hardware-entrepreneur/2017-07-05-032-why-manufacturing-in-usa-vs-china-is-becoming-interesting-with-scott-n-mille) (The Hardware Entrepreneur)
- [203: Design for Manufacturing for a New Invention Product](https://hardwarepodcasts.com/podcast/product-startup/2023-11-24-203-design-for-manufacturing-for-a-new-invention-product) (Product Startup)
- [Episode 274: Fold time back on itself](https://hardwarepodcasts.com/podcast/making-it/2020-08-28-episode-274-fold-time-back-on-itself) (Making It)
- [An Interview with Scott Miller - Sudden SinoAmerican Synthesis](https://hardwarepodcasts.com/podcast/the-amp-hour/2012-09-17-an-interview-with-scott-miller-sudden-sinoamerican-synthesis) (The Amp Hour)

## Citing this page

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