The Challenge
Context: The “K-Class” generation (Pre-Blu-ray).
These units defined the original Kaleidescape experience for DVD.
- Region Free: Engineered modified drive firmwares to handle global disc region coding.
- Upscaling: One of the first high-end scalers to bring 480p DVD content up to 1080p/i.
Forensic Engineering
The “Chewed Edge” (Texture Crisis): The plastic housings (Steman/Weddy) required both conductive EMI plating and cosmetic paint. The double-coating filled the texture, making edges look “chewed.”
- The Fix: We rejected the process instructions and forced the vendor to EDM the texture directly into the hard tool steel, rather than relying on paint texture. This ensured the finish survived the EMI coating process.
Team Orbit
- Engineering Lead: Erik Norris
- Plastics: Steman (Weddy Wang)
- PCB: Mars Platform Team
- Program: Rob Wudrick
Success Metrics
- $6,000 Tooling: Delivered the custom mounting bracket tooling at Steman on budget.
- $5,400 Avoidance: Saved EMI shield tooling costs by validating prototype tooling for initial ramp.
Project Artifacts
:::note[Specs]
- Media: DVD
- Resolution: 1080p Upscale :::