When I first arrived at Autodesk, the production line was begun only a month earlier. There were many places for improvement, but I determined the greatest gain by far was to improve the calibration of the UV projection system.
The original calibration process was visual and dependent on the opinion of the person assembling the system. My quick fix was to create an Arduino powered system to flash a green light when the correct focal length was achieved on the projector lens.

Testing proved that this process brought all printed features within 5 microns of intended geometry. More importantly though, this ensured all physical assemblies were at the same focal length. This made it possible to use software updates to push changes if needed, i.e. altering the scaling factor based on test data with a new resin.
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