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New Year, New Box, New You!

“Radically better”

As we move into 2020 we want to take a moment to talk about the latest version of the Box, version 1.3. We’ve dedicated much of the last year to developing it, and we LOVE it!

Our new v1.3 Box design
Behold version 1.3! Think it doesn’t look much different? Think again and look under the hood…

At the beginning of 2019 we sent 40 boxes around the world in our pilot. Following the feedback from that, and coupled with a wish list we had already built up, we identified a number of ways we could improve the Box.

At the same time we set ourselves the ambitious goal to build 1000 boxes by the end of the year. Building large numbers of the previous design wasn’t ever going to be practical, it was made up of a tangle of wires that we had to hand-wire ourselves and it relied on a variety of components ordered online from a multitude of suppliers. The Boxes were also subject to the occasional injury when transported around the world, so it’s suffice to say we had our work cut out!

Some of the ways we sought to improve the design included:

  • Better audio – louder and clearer!
  • Faster assembly time
  • Fewer parts
  • More durable design
  • Logging boops offline

And so we started work in the spring; Adrian worked on designing the PCB as a neat home for all the components that were previously crammed into the box, George developed the awesome instructional graphics on the board and worked on software improvements, and Charlie designed a new acrylic ‘skull’ and mapped out the positions for the electronics and how they would be mounted inside the Box. So here it is…

The new PCB…

We LOVE the new PCB and it has a few important features worth talking about. Importantly there’s no wires. Previous Boxes included a large micro-USB extension cable, aux jack, and loads of wires which got in the way. Now the jacks are tiny components that sit at the back of the board and are devoid of the tangled wires that criss crossed older versions. This means we no longer have to hand solder anything (Yay!) and the boxes will be far more durable, reliable, consistent.

The ‘Brain’ of the Box is now a neat stack of three separate boards: A Raspberry Pi 3A+ sits at the bottom, then there’s our main custom board and progress LED board (affectionately known as ‘Blinky Lights’) which slots in a right-angle socket; and finally we have a stacking header and plastic standoffs which raises the reader high above the main PCB just underneath the surface of the box. Primed and ready for Booping!

Our beautiful board (note the handy prompts to help you understand what’s what!)

There’s now a REAL-TIME CLOCK (RTC) too. Previously if a Box wasn’t on WiFi we had no way of logging when a Boop had happened because the Pi doesn’t keep track of time when it’s not online. So this new RTC allows us to timestamp a Boop and log it next time the Box is connected to a WiFi network.

Testing the board and speakers for the first time

Then there’s the DIGITAL-TO-ANALOG CONVERTER (D.A.C.). As the board says the D.A.C. ‘converts digital audio into analog sound for the amp’. This along with our super swanky and loud speakers make for waaaay better audio, that is free of static and incredibly clear. This alone makes the experience of using a Museum in a Box, particularly in noisy environments, so much better.

1000 Speakers!
1000 custom made speakers!

The new speakers not only pack a punch but also weigh a lot less which in turn makes them far easier to mount. V1.3 is almost half the weight of previous versions which will reduce both the cost of postage and it’s environmental impact when shipped around the world.

The new Skull…

A side by side comparison of the Museum in a Box design changes from 2018 to 2019
A comparison of the Box design evolution from 2018 to 2019

With our new PCB came the challenge of mounting it inside the ‘Skull’. Past versions required us to fix bits to the sides, top, and base with an opening on the underside. This was fastened by screws in the feet and some t-nuts that were an incredible pain to mount and often came loose!

The advice we kept receiving when talking enclosures was to injection mould it. The main benefits of that being a moulded enclosure is ‘preassembled’ and ready to put the electronics straight in. It’s also very scalable and would allow us to integrate snap fittings into the design for mounting components inside.

To explore this we did a lot of research into moulding and a bunch of work CADing and prototyping different enclosures. We also took a team trip to visit Protolabs in Telford and learned a great deal from the brilliant people there and received an exciting factory tour of their setup. We attained quotes but ultimately decided not to go with injection moulding for two reasons:

1. The upfront tooling cost is very high and hard to justify for the small batches we planned to initially produce.

2. The overall aesthetic of the Box has become part our identity. The ability for us to easily modify the design, and teach others to build the Box (such as our amazing Verizon volunteers!) feels much more appropriate for our scale and values.

So, having decided to stick with our laser cut look we needed to find a neat way to mount the PCB inside the Skull. The solution was to switch from a bottom opening to a front loading Box. We created a neat groove on the back panel for the PCB to slide into and sit neatly in the middle of the box, lining up with openings at the back for the micro-USB and aux jacks. The Box can now be opened, the PCB removed, and replaced in mere moments!

Get in the groove! The ledge the PCB slots and rests into, lining up with the aux & power jacks on the skull.

The extra front and back panels are held in place and made removable by using some neat snap rivets which can be removed from the outside. We used these rivets for speaker mounting too where before we’d faffed about with tiny nuts and bolts and a laser-cut stand.

Blinky Lights – We use these to indicate that the Box is ‘warming up’ and ‘ready to go!’

Other new features include a new progress LED board which is slicker and uses some recycled acrylic offcuts for the shims that we sent to the PCB manufacturers European Circuits. We spent a long time looking for the perfect light pipes to use with surface mount LEDs but ultimately decided to stick with through hole LEDs and our big green green LED. Why? Because they look bright and amazing!

New Packaging!

A new Box deserves new packaging to go with it. We revisited a previous design using a more compact container and an insert that conceals the power plug and various admin and try me cards so all you see when unboxing is your shiny new Box!

Finally there’s the latest version of the software. We’ll talk about this in more depth another day but we’re chuffed that the Box now boots up waaay quicker than it used to and includes more audio guidance when working through steps like WiFi and updates.

The new assembly time…

With our new design manufactured we decided to assemble the first 20 Boxes. We were blown away to discover that assembly now takes ~7.5 minutes per Box – a 2000% increase from the old design!

George and Charlie building 20 boxes in 2.5 hours!

In future this saving will enable us to fulfil orders quicker than ever before. The Box was intentionally designed for disassembly and as a result we proudly no longer use glue during the assembly process. The Box will now be much easier for people to disassemble and recycle at the end-of-life and we will share a breakdown of the parts and materials inside the Box in due course to make safe and appropriate disposal even easier.

And so with our shiny new Box design came our first test…

First boot up of v1.3… we figured out the Zeus print, eventually!

So there you have it, our new Box and the culmination of over nine months hard work. I hope that proves an interesting insight into some of the design decisions we made in developing v1.3. We love it and we hope you do too!

Our shop is now online so you can buy your very own v1.3 Box with a Make Your Own kit now! Kits are available in Individual, Educator, Small Org and Large Org options and colours include CMYK, Transparent, and Plywood.

Box colours range: Cyan, Yellow, Transparent, Plywood, Magenta, Key
Box colours include: Cyan, Yellow, Transparent, Plywood, Magenta, Key

Have a wonderful New Year from all at Museum in a Box.

📦🎁🎅🎄🧦🎉🛠️🏺🏛️🔌💡🔉🌰

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All boxed up [update]

Our brains have done a fair bit of milage recently with George travelling to LA for the Communicating the Museum conference and Charlie flying over to Belfast to talk at the Digital Tech, Young People & Heritage conference at Ulster Museum and also exhibiting at the British Museum’s 3D Imaging in Cultural Heritage conference.

In preparation we’ve spent a bit of time working on new packaging for what we refer to as the ‘starter box’ because it contains: the brain, an introductory print, and a mains plug; everything you need to get started! Previous versions have been bulky and wasted space which can make travelling with the box more challenging than it need be. We wrote exactly a year ago (gosh!) about our visit to MOO HQ where we worked on packaging ideas with their product design team and having now spent some time designing a new box we wanted to share a brief overview of our packaging evolution and developments:

Statues of Women in London – December 2015

December 2015: Early brain prototype combined with the statues of women around London set. We later decided to separate the brain into an independent starter box because the variation of possible 3D prints and postcards in the box is so great. This gives us more freedom now when packaging up each unique collection. 

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MOO Box – November 2016

November 2016: An experiment developed with Moo Ltd using their plotter machine and a square brain. This included a space for a set of NFC cards.

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February 2017: Starter box comprised of many laser cut layers of card. Solid but used an unnecessary amount of material, was heavy and there was a great deal of wasted space.

An object box made for the Jewish Museum London’s ‘Hearing History’ set

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Render of a foam insert design – July 2017

July 2017: Stacked foam insert, the brain sits above the starter introductory print and plug. We liked this foam design but for small quantities we’d need to laser cut and stack multiple layers which is both time consuming and costly.

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Development of a card insert – October 2017

October 2017: 

In this new design the brain sits above the insert, when you remove the brain the plug and print tucked away underneath are revealed.

We adapted the foam design to allow for the slightly bulkier Rasperry Pi plug. Doing this means we could easily change the plug type and send a starter box to almost anywhere in the world without the need for an adapter… it’s the small things that count!

The box is made out of three parts: the box itself (a), the insert (b) and the tray (c) glued to the underside of the insert. The real challenge was designing an insert that works with the many different plug adapters of the Raspberry Pi universal plug!

Raspberry Pi power adapter

The packaging is a great improvement on the older bulky and heavy box making it much better for sending in the post. Having travelled around with this new box however, we’re now thinking we can make it smaller still!

Hopefully this has been a brief but insightful overview for any packaging nerds out there!

C

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Charlie DoES Liverpool

Last week Charlie hopped on a train up to Liverpool to hang out with our tech lead Adrian, here’s an account of what he got up to:

DoES Liverpool

Having never been to Liverpool before I jumped at the chance to make the two or so hour train ride to visit Adrian who is based at DoES Liverpool, a maker space which he co-founded in 2011.

On arrival I was introduced to all of the friendly faces, claimed a desk and set my intro music to a piece by Frédéric Chopin (the space is rigged to play an audio file when you ‘tap-in’ in the morning). I was also introduced to the talking fridge, the gesture bin and the internet-connected coffee machine. Welcome to the wonderful world of DoES Liverpool!

The space is divided between the co-working space and the workshop which has a wealth of kit including two laser cutters (Gerald & Sophia) and several 3D printers. I arrived with a list of things I wanted to get done and so wasted no time with cracking on.

Cardboard Experiment

One experiment I had a chance to play with and develop was a cardboard Museum in a Box. I’d prepped a flimsy mock-up in London and was pretty chuffed with the outcome so decided to refine a neater version in the workshop at DoES. This was also a useful opportunity to try out a different internal configuration and a new way to access the tech inside the box.

Architecture

Being a bit of an architecture enthusiast, spending time in Liverpool was a dream because the buildings vividly tell the story of a busy port city, its development and importance at the time of its height in the British Empire. I’ve dreamed of an ‘architectural box’ for some time now and a tour around the docks provided the inspiration to start just that. Towns and cities across England are littered with great lessons and examples of great architecture but unless you can decode what you are looking at it’s hard to truly interpret and appreciate it. The author and illustrator Matthew Rice says it nicely:

‘Once you can speak any language, conversations can begin, but without it communications can only be brief and brutish. The same is the case with Architecture: an inability to describe the component parts of a building leaves one tongue-tied and unable to begin to discuss what is or is not exciting, dull or peculiar about it.’

Garstang Museum of Archaeology

Adrian and I managed to squeeze in a trip to the Garstang Museum, a museum named after Professor John Garstang, who founded the ‘Institute of Archaeology’ and associated museum in 1904.

Despite its modest size it’s packed with fascinating objects, most of which were excavated by Garstang in Egypt, the Sudan, and the Near East; the collection also contains almost twenty collections of glass-plate negatives relating to Garstang’s archaeological work in these areas. Several of the images have been enlarged and line the walls of the museum providing a fantastic insight into the world of archaeology in the early 20th century.

Something that struck me was the amazing collection of Shabti that are on display in one of the exhibition spaces. Shabti were funerary figures who accompanied the deceased to the after-life, left alongside them inside their tombs. The poorest people may not have had any but even those tombs of modest size would have contained at least one or two Shabti. Those on display in the museum clearly show the range of Shabti and their corresponding value because of the materials used (wood, stone and faience) and their size (from ~10mm up to ~30cm), it was great to see such a diverse representation of people come together within one display case.

If you’re in Liverpool and have a spare hour I can absolutely recommend heading to the Garstang but be sure to plan carefully as the museum only opens on between 10am-4pm every Wednesday.

Taking five after a long day of making and learning in Liverpool

Back at DoES I was really enjoying being able to work on an idea in one room and nip next door to quickly mock-up a prototype in the workshop so much so that I was still laser-cutting minutes before having to leave to catch a train back to London. I was able to work on and develop some fun ideas including an architecture box which I’ll share some more info on in due course. Thank you Liverpool!

That’s all for now. C

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brain design packaging prototype

Design for Disassembly

The design of the Brain has evolved as components have been added, removed and replaced. We are improving accessibility to the tech inside, and coming from a sustainable design background I wanted to challenge myself to produce an experimental Brain where the products’ full lifecycle is factored into its design. So, here’s what I’ve been up to…

The aim was for the Brain to do the following:

  • Provide easy access to the electronics
  • Enable components to be quickly changed or modified
  • Completely disassemble easily
  • No glue!

First came lots of planning, then sketching and then I got to work CAD-ing up the design. Creating the design digitally first was beneficial as it provided the ability to position the components in a virtual space, adding the wires also helped to visualise how crowded the Brain would be.

The most notable change to the design was how the Brain is held together. We currently glue panels with interlocking finger joints, but for this design they slot into channels on the top and bottom and are pulled together with brass standoffs in each corner. We often get asked how the Brains work but it’s not always easy to demonstrate, we therefore laser-cut the panels in plywood and clear acrylic making it clear to see what’s going on within the skull.

Panel flat-lay (excluding mounting nuts/bolts)

After some light sanding the Brain assembled for the first time and the components easily mounted to the dotted grid. Most importantly the feet can be unscrewed and the base panel lifted providing easy access to add and remove parts.

This Brain has enabled us to improve upon components that were appropriate in the past but no longer live up to our requirements. One example is the power socket which was previously glued to a laser cut shim and had a tendency to come loose, we managed to source a panel mount version which now works a treat (see pictures below).

I’m very happy with how well the design turned out, I’ve lost count how many times I’ve disassembled and reassembled it. We’ve primarily been using it as a prototyping Brain to quickly test out components and content but it’s also made us big fans of acrylic and we now have plans for a colourful set of CMYK boxes!

That’s all for now,

C

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All boxed up at MOO

We recently paid a visit to our friends at MOO HQ which is only a stones throw from our Bloomsbury base to meet up with Toby Hextall and Phil Thomas who are the go-to designers on all things product and packaging. We wanted to get some packaging tips and also start prototyping a few concepts and Toby and Phil were kind enough to help us out.

 The Moo office is a beautiful and inspiring place and so we couldn’t help but take a few snaps before getting down to business.

Moo Entrance

After a catchup and some brainstorming we set to work on a first iteration container to house a brain box and set of MOO’s NFC cards. They have some great kit and we were able to prototype a set of packaging inserts and a card box using their Graphtec FC2250 Flatbed Plotter. The machine cuts and scores each piece of card very fast and accurately and it also works with an inDesign plug-in making the whole experience super smooth. 

img_8844

We learnt a lot about product packaging in a short period of time and worked through several iterations of inserts designed to hold a ply brain box and business card box. Whilst refining a design we also tried out various card stocks including thick corrugated sheets and recycled craft card. We discovered that the insert had a tendency to rise up around the plywood brain box so added two flaps that the brain would sit on top of to prevent this rising from happening. The box of cards also caused the insert to flex and so we tried out different tab widths as well as corrugated card to work around that.

Below is a video put together to show the machine we used to cut the inserts and the iterations in a little more detail:

We’re excited to see what else we can produce and how we can develop our packaging prototypes. We hope to spend some more time with Phil, Toby and the rest of the team in the future and we’ll keep you posted as always as things develop. Exciting times!

C.

charlie with phil