Engineering porn: how to create a Mac Pro

Apple submitted a video demonstrating the process of creating a new Mac Pro makes brain. Today we have a closer look at the path shown by this product on-stamped blanks embryo to finished computer. The uniqueness of the production process, Apple is not the fact that they use some sort of magic. Not. Feature Apple - the ability to adjust production in sverhtehnologichny unimaginable scale. Typically, these requirements put only to aerospace and medical tech industries.

When creating a new Mac Pro the company had to develop a completely new technology for it. It all starts with the formation of Mac Pro cylindrical body. Here comes in the hydraulic deep drawing.

First workpiece impart suitable shape. In the case of the Mac Pro production becomes much more complicated. It is necessary to produce large amounts of deformations of the slug, while preventing occurrence of cracks and ruptures in the metal. For this process crushed into a plurality of small operations, in each of which an aluminum ingot is gradually brought to the desired shape.

To create a body of such a form Apple could use a simple process - recess. However, you understand how this technology is ineffective in terms of the number of sacrificial metal (read at your leisure on the production of Soviet aluminum pans :) - approx. Ed.). Deep drawing allows you to create detail desired shape much faster. Then the surface of the body is adjusted to the ideal - cleaned, polished and sent for further refinement (vytachivanie technological holes and anodizing).

And now everything in order and with pictures.

Here we see the blank from which it starts. It is difficult to imagine that this will turn into a dull washer glowing cylinder. First Source said that specifically, these two images can not be obtained from the Apple Production because the uniforms of employees and the situation in the workshop in the background does not meet the standards of the apple company.

The same goals, but after 4 or 5 stretching. I still do not really like the Mac Pro.

And here the drawing process. By the way, fire extinguishers and oxygen tanks do about the same.

Before you licking the surface of the cylinder. No man to cope with such precise and fine work, and are getting into the act machine tools with numerical control (CNC). Judging by the picture, it is one of two dozen machines Mazak NEXUS, installed on the production lines of Apple.

Even Mazak can not bring the body surface to Apple standards. Here the work of polishing machine Kuka. He will make the cylinder surface is literally a mirror.

Incidentally, a similar method of polishing is used in the industrial production of high-quality knives. Thus, the product acquires the desired profile and correct sharpening. The accuracy of the equipment used in these steps, you can not imagine.

Why to put something on a perfectly polished surface of the body? The fact is that this body will soon be drilled, and the material will protect the surface from mechanical damage. In it there are no cutouts for the power button, ports and so on. If we make a milling operation before polishing, the sharp edges of the cut-outs are literally torn to shreds polishing heads.

Your Mac Pro to operate the machine again in the machine. You can see how to make it a notch panel ports. It may be noted that in places where the work drill, protective film carefully removed. Presumably this is done to ensure that the protective coating does not burst when the drill because of this surface near the cut-outs will remain perfect.

It would seem a trifle, but in fact is taken into account everything. Put a thousand such smart decisions throughout the production process, and you will understand why Apple machines are always at the forefront of high-precision production.

Corps reached the anodization step.

metal anodizing - this is not some sort of spray to the surface. This is a real transformation. Through detail, is placed in an acid bath, a current is passed. As a result, pure aluminum surface is oxidized, turning into an aluminum oxide. The point is that with such a treatment of the oxide film obtained porous. The pores can be forced dye any color, and the particles of the dye at the same time perfectly sealed surface.

Holders that host body, made of titanium, and you can see how multiple operations anodizing distorted their color.

other details

The charm of high-precision technology and can be found in every detail Mac Pro, but they are difficult to find. Apple is not eager to reveal all the subtleties of production. We would be very interested to learn about the process of creating the cooling systems, because such non-standard forms and strengths by volume for certain restrictions are forcing engineers to find a completely trivial solutions.

Here we face the famous triangular thermal core Mac Pro - it is used to remove heat from the computer. Gyson machine is used for processing the surface of the thermal core. Apple often changes the operating procedures of equipment, allowing it to work more efficiently. The mechanical arm in the picture is made by FANUC. You will not see such a robotic equipment at Chinese Apple factories where almost all machines are serviced by people.

Gyson at work. The jet of air under tremendous pressure rolls on the surface of the workpiece sand particles. This happens sandblasting.

In the assembly of boards Mac Pro is nothing special. Such manufacturing processes exist for a long time and well-debugged. In contemplation of this working robot experience a shock of the speed with which it is soldered to the board elements.

Even the assembly plant is constructed so that the most efficient use of space. Details for the assembly fed from under the table. Typically, the space under the table is not used, but not here.

Application of the product name on the case made fiber laser. Used in this production lasers have movable heads, which greatly accelerates the process of engraving.

Apple's ability to establish accurate and technologically advanced production of this magnitude is really amazing. Someone might say that such budgets can bring the most advanced technology, but Apple-like approach to creating such a thoroughly highly detailed and thoughtful production can not be bought, it needs to come up with and implement, and then the money is no longer a decisive factor.

(via)