four weeks ago we hired a design team to help us design a customized cage for the modules. We could have always opted to go with the swiss case and produce but even they have been modifying that as well.
The design team ran us up quite a lot in a week or so and we ordered (quick turn from rapid sheet metal in NH) 400+ cages.
The designers did not leave holes in the cages for airflow to pass over the top of the boards (chips/chipsinks) but more over just holes which were the exact size of the heatsink fins.
So with the chip's data sheet specifying airflow/thermal dissipation 30% on top and 70% on the bottom this would work and chips would over heat. So we're stuck with 400+ sheet metal cages that dont work - we got quotes on cutting out the pannels of the cages, drilling holes etc.. So what's the quick fix to fab 400 sheet metal cages.. New heatsinks.
We ordered new heatsinks with more fins and 3mm fin height difference allowing us to utilize that gap for chipsink thermal flow. New sinks took 4 days to come in, cut to length extrusion, and 2-3 days to CNC from a nice guy with great pricing who has become the end of the day bitch station of all the things that went wrong during the course of the day. So the next week became a early morning and late evening pickup of heatsinks.
designers back in the lab charging us to fix the mess they made and we told them this time - make it like a fence. So they finished after a few days and sent the designs back to Rapid - who turned it around in a week (not very rapid) and sent the first 100 units over on tuesday and what did we find out.. the designers did not add the 2nd and 4th screw holes on the back side of the cage..
Called rapid they said send it back - quoted a week or two in turn around.. called larger shops they weren't available didn't have any time for quick turn runs...etc You're thinking so what .... it's only 4 screw holes you can drill them yourself, not quite. The holes need to be exact to the mm because if they are off by .2mm than your backplane wont fit in the right way and eventually lead to more problems.
CM offered up a quote of $10 per cage to have a few guys they know come in and do it. Also referred us to another character that came back rather too quickly with quotes in thousands. Trying to do several ourselves, some came close but nothing professional and came out with correct holes spacing but bent sides etc... just a world of crap.
In the end the nightly complaining at the CNC shop (heatsink pickup round 6) we mentioned it to our cnc guy and he was like ... "we can do that, $2 a cage done in 48hrs."
The CNC was already set to drill and tap the holes on the sinks which was the spacing it needed to be on the cage, so he was able to make a sheet metal template for manual drilling and had one of the shop minions do the drilling.
Moral of the story - ask everyone, call around and get quotes, but ultimately the guy that runs that CNC is gonna know what to do and how to handle shit situations.
This is one of several factors that has attributed to our delayed status.
Transparency...
This is EXACTLY what you should have been doing all along. Keep it coming. Please!