Case StudyMicrosoftEngineers andModel-Makers
Utilize PolyJet™
Technology toRedesign Surface
Pro 9’s KickstandHinge

The primary objective has
always been to identify thequickest and most efficientroute towards validating adesign solution. The J850
Prime has emerged as aleader in this domain, enablinga greater focus on the design
aspect rather than theintricacies of fabrication.
Mike Oldani

Model-Maker, Microsoft

2 2Customer Profile
Located in Redmond, Washington—Microsoft’s
Advanced Prototyping Center (APC) is a 26,000square foot prototyping facility sandwiched
between the Industrial Design and Engineeringgroups. This team of highly passionate makers
acts as the translator between concept andreality. Utilizing a multitude of manufacturing andprototyping tools, the APC focuses on efficiently
creating solutions and prototypes to answer
business questions. Following the mantra of“Fail Fast” the APC is responsible for quickly
generating confidence in development decisions
for Microsoft’s designers, engineers, and partners.
3D printing plays an integral part in Microsoft’s “FailFast” development process and PolyJet models
are a part of our daily routine.
Challenge

Developing a new Surface Pro hinge is anespecially complex prototyping challenge due tothe small size of the individual components which
require precise engineering and access to toolsthat can produce parts with a high degree ofaccuracy. While traditional prototyping methods
such as CNC machining or metal injection molding(MIM) can produce highly accurate parts, they are
not efficient enough in terms of time and resources
to quickly prototype and test multiple designs forthese types of components, something that is
crucial in today’s product development landscape.

Document
Case
StudyTitle Here

Hardware development requires input from a wide
range of subject matter experts to ensure thegreatest chance of success for getting a productto market that fulfills the original design andengineering intent. The latest Surface Pro 9 is afitting example of how different teams collaborate
to engineer new and improved features for
Microsoft devices, features like the easy to detachmagnetic type-cover keyboards and the innovativerefinement of the Surface Pro 9 kickstand hinges.

The kickstand is one of the iconic features ofthe Surface Pro 9. The hinges that attach thekickstand to the device play a crucial role increating a premium user experience. Hinges need
to be compact and lightweight, yet strong enoughto support the device across a wide range ofadjustable angles reliably with repeated usage.
The latest iteration of the kickstand hinge wascompletely redesigned for Surface Pro 9 using
fewer parts than previous versions, yet providing
the same user experience, giving the users theability to adjust the device to their preferred viewing
angle. This smooth, almost infinite angle featureallows for great flexibility in various use settings,
such as on a flight watching a movie, at homecomposing a Word doc, or creating art in and outof the studio using the Surface pen.

Exploded hinge

3 3Solution
In the past, prototyping complex mechanicaldesigns required a significant amount of time andresources. With the introduction of the Stratasys
J850™ Prime printers, this process has becomemuch more efficient. The J850’s advanced
dimensional accuracy allows for quick iteration ofeven small mechanical parts, providing a fasterand more efficient solution to prototyping complex
mechanical designs. Microsoft engineers andmodel-makers collaborated to develop a uniqueprototyping method, digitally upscaling hinge
assemblies, and then printing these larger-thanlife units. The accuracy of the parts off the J850
system meant there is little to no post-processing
needed for assembling the prototype, allowing
for rapid validation of designs. The J850 printerhas proven to be an invaluable tool in the productdevelopment process, enabling precise fit checksof complex mechanisms designs, and range ofmotion studies. Couple that with its fast-printing
speed the J850 has helped remove the bottleneckin product development for the designers,engineers, and model makers.
Business Impact

Mark Honschke

3D Print Lead, MicrosoftDocument
Case
StudyTitle Here

Surface devices are conceived from an idea, built
many times over, and perfected before heading
off for factory production. The J850 Prime hasboosted confidence in the overall prototyping
process expediting the turnaround time for precise
parts, allowing engineers to become more deeply
absorbed in the form and function of the design
versus worrying about the details of a prototype
construction. In the case of the Surface Pro 9’s
hinge, the ability to upscale and print components
on the J850 has allowed for faster identification ofpotential failure points and enabled exploration of
more innovative design paths, ultimately leading toa more premium user experience.

Part to part accuracy is
crucial when developing
mechanical features during
product development.
This ensures the prototype
experience matches thedesign intent as closely aspossible. Due to the vast
improvement in accuracy
from previous PolyJet printergenerations, our mechanicalengineers routinely ask
that we print their parts
exclusively on J850
technology.

Microsoft 3D Printing Lab4Microsoft hinge

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