The Making of the Panaflex Platinum
Camera
by Michael Frediani, SOC
This article is the first in a series
that will take the reader behind the scenes, revealing the
manufacturing process necessary to build the equipment we
use on the set.
In 1972 Panavision introduced the Panaflex
camera after four years of research and development. Four years
later the Golden Panaflex debuted with an Ultraview reflex viewfinder
and a "G" Drive system featuring replaceable circuit boards and
Panaglow (receiving the SOC Technical Achievement Award in 1992).
Introduced in 1986 as part of the Panaflex
family of cameras, the Platinums featured an improved viewing
system, quiet compact drive, annunciator panel, CCD video assist
and time code, items previously unavailable on earlier Panaflex
cameras.
Let's take a look at the multi-step production
process involved in creating the Platinum. First the bodies are
supplied by a sub-contractor who begins with molten aluminum
#356 cast into 25 units weighing just four pounds each (photo
A), and then shipped to Panavision in the San Fernando Valley
to be built by hand and machine to the finished product. The
already familiar-looking casting is attached to a machining fixture,
part of the Computer Numerical Control Machine (photo
#1) which carries out the automated machining process. The
CNC itself is controlled by a computerized program called CAD-CAM;
its purpose is to automatically drill and mill each casting.
The CNC device contains 21 tool stations which house taps, drills
and endmills (photo
#2).
As the first of 25 castings is placed within
the CNC each designated tool station performs its dedicated tasks
as the CNC turns the camera body on an X, Y, Z and A axis rotation.
There are 122 machining operations performed
on each casting which require 9 different machine set-ups (photos #3, #4).
Total machining time per unit is approximately
25 hours. Exacting tolerances are maintained: .001" which is
three to four times smaller than that of a human hair. After
each machine set-up a first article inspection is performed.
This process involves a visual review in addition to a computerized
analysis of the previous machining operation while the unit lies
on an extremely flat and level surface; part of the "Coordinate
Measuring Machine" (photo
#5). Its probe device, directed by a technician, makes physical
contact with various surfaces (photo
#6) emitting touch signals which are relayed to a computer
monitor. The probe checks tolerances to within .0001" and if
any incongruities are found, necessary corrections to the computer
program are made before machining is commenced.
Once approved the housing is black anodized
and painted to prevent corrosion and to avoid reflections. The
next step in the building process is the installation of wiring
components (photo
#7), which is carried out by hand. The lining is installed
next and then the 'mechanism plate' is put into place. Dividing
the camera interior in half longitudinally this stable aluminum
tooling plate allows mounting of the motor assembly (photo
#8) on one side and the movement mechanism on the assistant's
side of the camera. The actual motor and circuit boards are manufactured
at Panavision in Tarzana, CA.
The camera movement is assembled from 105 separate
pieces (photo
#9) machined to extremely close tolerances. The fitting of
the individual parts is done by hand to tolerances of .0001" and
each one takes up to 130 hours to assemble not including the
manufacturing of the components. The aperture plate is crafted
from stainless steel and then hard chrome plated for wear resistance
and smoothness.
The mechanism plate assembly consists of four
sub-assemblies: The shutter dissolve mechanism (shutter blades
are .012" thick), the movement drive, the sprocket assembly,
and the mirror bracket assembly. All of these sub-assemblies
require extreme tolerances of just .0001" to .0002" in order
to insure the flawless performance of the camera.
The optical viewing system consists of the
focus tube which is a permanent component of the camera, the
extension viewfinder and the hand-held eyepiece, consisting of
293 machined parts and 30 optical components and sub-assemblies.
Optical testing is carried out by an optical technician (photo
#10) with the aid of a centerline scope. Attached to the
focus tube in place of the eyepiece, it checks the positioning
of the viewing optics and centerline in relation to the film
frame. Once satisfactory results are obtained, film is exposed
to check centerline orientation. Next a steadiness test is performed
by filming a grid chart in two passes (photo
#11).
After the first exposure the film is rewound
in the darkroom, the grid chart is off-set slightly and then
the film, without the camera moving, is exposed a second time.
After developing, the negative is projected onto a screen and
visually checked, making sure the grid lines do not jitter.
The final step in this manufacturing process
is to place the camera in a sound testing booth (photo
#12).
With a 50mm lens mounted and facing a microphone
3 feet from the film plane, the camera is run without film. It
should register no more than 17db. With film the camera should
be no louder than 20db prior to its being released to its first
production job.
The Platinum camera body alone is the end result
of approximately 500 hours of dedication and skill. The styling
and individual craftsmanship exhibited in the Platinum rank it
among the most popular cameras in use today.
Thanks to Jurgen Sporn, Panavision's Vice
President of Manufacturing for his cooperation and assistance
in the preparation of this article.
Photos by David Robman, SOC
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