My brain's
on fire. Hey, it's me, Destin. Welcome back to Smarter Every Day. We are right in the middle of a
manufacturing deep dive series. And you may recall in a previous video, we went to a progressive metal stamping
factory, and this place was incredible. They took coils of metal and they rolled
them through these big presses with dyes and they would stamp
out thousands of parts. It's an incredible process. But one of the challenges to a process
like this is it takes an incredible amount of time and skill to create
these progressive stamping dyes. Today, we're going to
talk about a new process. Now, we're not going to get the same level
of accuracy or speed as we did in progressive metal stamping, but we are
going to be able to iterate and create parts quickly, like change the part, which
is an incredible asset when you're developing something or making
a small number of parts. So today I'm super excited to continue the Smarter Every Day deep dive series into
manufacturing, and we're going to learn about something called
incremental sheet forming. The intricate details of how this process
works blows my mind, and I've never seen this stuff on the Internet, and I think
it's going to blow your mind as well. So let's go get smarter every day and learn about incremental sheet forming, or
as this company calls it, Roboforming. [Guitar Riff intro song] So out in L. A. there's this company
called Machina Labs. And after a little bit of back and forth on the intercom because people are rightly
suspicious about a guy walking up with cameras to a secure facility, they
eventually let me in. Oh, they opened it.
Oh, nice. Okay, we're in.
So this is Bobby. He's the one that reached out after seeing
that I started a manufacturing series. He introduced me to a couple of his
coworkers who helped me get signed in. And then we headed upstairs to the office
portion of their lab/factory, where I met Ed and Boback, two of the
founders of the company. Ed is the CEO and has an interesting
background in software, and Boback leads the technology partnerships and has
a PhD in Materials Engineering. Both of these guys are astoundingly sharp. So my understanding is you guys have a way
to create shaped metal by forming it by, I don't know how to say it, touching it
in a very special way is what I'll say. Let me just draw it right here. So you guys have a plane of metal and you bring two tools in and you
can touch the metal like that. And depending on the position of this... What do you call these tools? [E] I call them end effectors, but forming styluses, but yeah, end effect
or forming end effectors. [D] Okay, got it.
So when these two end effectors come in and they put force right here,
you can deform the steel in there. And if you do it in a certain way, I'm
assuming, I haven't got here yet, but I'm assuming the position of
this versus this matters. [E] Yes. [D] Okay, and so you can do things
that are really interesting. [E] Yeah, so I think the best analogy that I can think of, how a potter, you have a
clay on your turning table, and the potter pinches the clay with their finger and
slowly deform it. That's what we're trying to do with sheet,
but it's a very strong sheet and it requires thousands of
Newtons to deform it. Deformation with the pinch, it can
be shear, it can be stretching. There's a combination of different
mechanisms happening until it gets you a, part that you want.
[D] So, you have access to more interesting geometries, but the trade-off is it takes
a little more time to make the part. It takes a little bit more time to make the part, but if you take into account the
fact that you had to make a mold to make the part, then in a lot of cases, up to
even thousands of parts were faster. [D] Really? [E] Because you can start making the part
two hours after your design is done. With the mold, you have to go
through iterations on the mold. Usually, the design of the mold is also slightly different than
the design of the part. Because the sheet has a spring back, you
stamp bit, it comes off, it moves again. Your mold is usually different
than your actual geometry. It's just not the negative
of your geometry. By the time you're going through those iterations, you're spending hundreds of
thousands of dollars, you get your part, you might be
even faster just forming with us. But then once you're forming the part, obviously, we're
slower than the stamping, stamping is a few, seconds you get your part. [D] This is great for development
and low rate initial production. [E] Yes, I think that's the first
area that we're going after. But you would be surprised
where the break even point is. [D] it's further down the
chain than you think. [E] it's further than the chain you think. [D] Ed took us downstairs to see the robots. But before you see it, I want
you to think about this. This is not like these guys
invented this overnight. This is the result of decades of
research by professors and scientists. And in fact, if you look at the old patent history, you can see patents from Japan,
Europe, Finland, all over the place. People have been trying to figure this
out, and we're just now getting to the point where they can crack
the code on how to do it. [E] Ford, Boeing, Nissan did some R&D work in this, but nothing really
commercialized out of those efforts. [D] So you're running KUKAS? [E] We're running KUKAs at the moment. The robotic system is KUKAs,
but we also can use Phanax. You can see on the other side,
those are Phanax robots. We are robot-agnostic. We pretty much basically build the whole
control system for the robots from scratch, so it's not dependent on
any features that the KUKA has. [D] It's like a dance. Oh, that's amazing. It's different than I thought. It's actually pushing. Sorry, I'm being rude.
I'm Destin. [M] Mark.
[D] Mark. What's up, man?
[M] Nice to meet you. [D] Nice to meet you.
How are you doing, man? Can I put a mic on you?
Are you cool with that? [M] Sure. [D] Can you show me what's
happening over here? [M] Yeah. This is incremental forming. [D] Yes. Incremental metal forming?
[M] That's right. It's a two-millimeter aluminum sheet and there's one robot on each
side and they're pinching. It's a lot like a potter's
wheel, spinning like that. But here the tips are moving
instead of the work piece. It doesn't have to be round. You can push any shape you want. Layer by layer, we're stretching and pinching and pulling whatever shape
I want here out of this metal. [D] The triangle here is coming out of plane.
[M] That's right. [D] Which means this one over here, are
there any optical lockouts I need to be. Aware of?
[M] Nope, you can walk right up to it. [D] Can I.
Walk here? [M] Yep.
[D] All right, thanks. [M] Just try not to get between
the robot and the sheet. You should be good.
[D] Yes, sir. This one is pushing.
[M] That's right. [D] Do you have a force gage
on this end effector? [M] Yeah, there's load cells on both robots, so you can feel exactly
what they're doing. Here, you can see over
here what's going on. This is the forces that both
robots are feeling right now. [D] Okay, so can you tell me
what colors are what? [M] Yeah, there's the Z component, the in-plane component, and then
green is just the total. [D] It's pretty easy to understand the force
is pushing into the plate, but the in-plane forces are the side-to-side
forces as the thing moves around. [M] There's robot number one here is the one
that's pushing, and then robot number two here is the support
that's on the other side. What you could do is you could do this
process with just one robot, and you could just poke in metal and basically
do a bunch of work by stretching. [D] But the boundary conditions.
Does it work? [M] Then you load the whole
thing up in tension, right? So what we're doing by having a support
robot on the other side is you pinch, and so you localize all the force just between
the tips, which reduces tension on the sheet and makes it so you can
form a lot more accurately. [D] That's amazing.
Okay, what Mark just said was crazy, and I have a little visualization here
to try to help me understand it. This is just fabric on a sewing frame.
Check this out. If you push against this thing,
it's going to tent out, right? This is going to deform.
Obviously. This doesn't behave like the metal does,
but it's going to deform out there. Now, when people work with metal, they use
something called breaking in order to locally deform the metal past
its yield strength, basically. They make a permanent deformation. What they're having to do in this case is
because they're poking on one side, if you were to push so hard that you
deform it, it would tent out. It'd be really weird, right? So they're locally doing it by putting two
end defectors right next to each other and just yielding it right there
in that little bitty spot. That's really hard to do when you have forces on both sides and
everything starts to move. So what they're talking about is wild
because when you break metal, you normally have a rigid datum, and you bend over a
corner, they don't have a rigid datum. They're moving things around,
which makes this complicated. So one is pushing, so I would expect a positive force
or compressive force on that one. And this one, if it was just holding in one position, would you just
hold the robot here until it feels forced from the other side so that you know
that you are actually pinching? [M] We get pretty fancy about it.
We're basically... Because should I talk
about all this stuff? Am I.
Allowed to do this? [D] Well, should I let him do it since
it's ultimately his authority? [E] No, I think Mark knows, yes.
Go ahead. No, continue. [M] Yeah, really, there's control systems on both of these robots where we can
plan their nominal trajectory. That just is the theoretical
what they should be doing. They feel the forces, and we use that to update to make corrections
to the trajectory basically. [D] Continuous
feedback. [M] Yeah.
One of them is correcting for its own deflection under load because
they're not infinitely stiff. The other one is trying to hit a
target pinch force that we set. [D] In super simple terms, the first robot is supposed to get to a certain point in
space, and the second robot is supposed to push at a certain force
required to bend the metal. That's interesting, but the problem is
once you start pushing at those levels of force, the robot itself starts to bend,
so you have to accommodate for that. [E] You have two robots on a
pretty large envelope, right? The envelope is 12 foot by five foot. Getting two industrial robots to be very
accurate in this envelope is one task that we have to do through a lot of
calibration and proper kinematics. But then the moment they start touching
sheet, the sheet will resist them. These robots are pretty new, though. You can imagine every
joint slightly deflects. There are controls and mechanisms that
basically compensate for that deflection so that the robot stays accurate
under dynamic load. Sometimes, depending on what sheet we are forming, it can be like 20,000 Newtons
of force that you're applying. It's like as high as the weight of a truck on a very small end effector
on the forming side. Under those loads, robots sometimes
deflect 6, 7 millimeters. You want to pinch a sheet that's only two millimeters or half a millimeter,
so we have to adjust for that. There's a control loop that uses the force
data, some of the other data to constantly figure out how it can stay accurate
and pitch the sheet the right way. [D] You just blew my mind a little bit. There's a lot of math here. Is there a robot around this corner? [E] There's a robot, but it's not
running at the moment, but, you can.
[D] Let's do it. Okay.
If I understand what you just said, there's many ways to arrive at
this point with this linkage. [E] Yes.
[D] Okay. If I arrive at this point and apply 5,000 pounds in that direction, I'm going to
get a certain radial deflection here. I'm going to get a certain
radial deflection here. You have to also determine how you get there in order to
anticipate the deflection. [E] Yes. [D] When you have a robot like this with a lot
of different joints, you can be in one location, but you can get there
many different ways, right? It's funny, but you see
what I'm trying to say. Think about it like this. If you've got 5,000 pounds of force that's
in line with this first actuator here, there's not going to be any
torque applied to it, right? But if you think about that second
actuator, the offset between the force and the actuator will determine the amount
of torque that that thing has to resist. And the same thing applies to that third
actuator down here, and all of those forces eventually get transmitted
down to the base of the robot. If you think about how these actuators work, they're all made up
of motors and gears, right? And if you were to zoom in, you would find
that these gear trains are imperfect. If you have a driving gear here, if it were to stop and reverse and go the other
direction, you would find that there's play between the gear teeth, and that
causes something called backlash. Watch the robot draw this shape. Now think about how the motors change direction at different
moments along the Polygon. Now think about the loading that's happening in the robot arm
as it changes directions. It's a pretty complicated motion
control problem, isn't it? Backslash is also something you have to
take into account with linear actuators like this screw system here that's
moving this big robot back and forth. When you move one way and then the other, you've got to take into account
backlash there as well. Okay, so not only do we
have issues with, the actuators themselves,
we also have issues, with the arms themselves.
Think about this. If you've been on a ladder and you've tried to drill something in really high
like this and your arm is all weak because of where you're at, but if you're up here
and you really put your power behind it and you line everything up, you don't
deflect as much and you get more strength out of it, all these
things factor in as well. So not only do you have the. Actuator movements. You have the rigidity of the arm itself. [E] There's two types of accuracy. Get the robot to one point, but then also
accurately move from one point to another while the forces are
changing on the robot. With the load, now there's an extra like, okay, the joint A1 not only need to be at
60 degrees, they need to be at 60.1 or 60.2 degrees, depending if at the end, the
factor is facing a 5,000-pound force, and including
that into the kinematic calculation. [D] That's hard.
[E] It's fun. It's a fun thing that our
robotic team is working on. [D] If this is at zero degrees and I'm pushing
into that, are there many different ways to set up the robot to get there,
or is there only one way it can, be set up?
[E] No. Because we have seven axes, there's unlimited ways to
get to that point with different poses. [D] What do you do? Do you pick a few things and
say, This always has to be here, this always has to be here?
[E] No. There's so many cool things. You can just choose, randomly choose,
or you can optimize, for example, for a stiffness in certain direction
that your force is going to be. You say, Okay, move the robot and the
rails so the joints are the most stiffest combination to apply the most
amount of force without deflection. You have a function to
optimize at that point. You can part of your kinematics, you can
figure out what exactly you want to do. [D] You're a wicked smart dude.
[E] No, I'm not. [D] This episode of Smart Every Day is
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the block of aluminum here. Thanks for sticking around for that build. And thank you for considering supporting
the sponsor because you're smart. You know what's going on here, and I'm grateful that you would
consider supporting. Okay, that's just all the robot. Now we have to think
about the metal itself. If we have a piece of metal and we push
on it, it's going to deflect, right? If we hold it at two locations and we push on it, it's going to deflect
in the middle, right? What happens if we're holding it here and
here and we have to push on it down here? You're not in the middle,
you're way over here. You're going to get a different
deflection curve all along the way. Let's go back.
To my little funny. Piece of fabric here, right?
Think about that. It's one thing to do it for a beam. That's what's called an
indeterminate deflection beam. Civil engineers are really good at that. Think about a plane. It's way different. Planar deformation is hard. So if I were to push up in the middle of this thing, I were to get a deflection
right there in the middle, it's going to be different if I'm over here at the edge
because you see the angle is different towards the edge than it
is towards the middle. It's hard to see this, but this is also
something that has to be taken into account when you're doing
all these calculations. What do you call it when if I were to take a sheet and I were to touch in the middle,
I would get more deflection than the edge? Is that edge effects?
Is that what that's called? [E] I think we call it boundary
condition effects. [D] That's what.
You guys call it? [E] Yeah, but you're right. Boundary condition affects the
accuracy of the parts that you get. We have a whole software stack
that tries to account for that. You can imagine you form a
part, you can then scan it. Actually, the same robot
scans it afterwards. [D] To do quality? [E] To figure out, yes, exact quality, or
to just figure out what it formed. To update the model. Then it will be like, Okay, I formed this. These are the areas that were off. That means maybe I should have pushed more in some areas and pushed
less in some others. It can manually iterate on that or keep
generating data and then later create a model that would tell you, Okay, in order
to form this geometry and this location in the sheet, you need to actually
form a completely different part. In the end, you're going to actually get the right part with all these
things we talked about. [D] You might over shoot
here, undershoot here. Just like injection molding or something. All these processes have that. Because it's actually rolling, isn't it?
[E] Yes. This is a specific one does. There are other ones that we have
that roll in different ways. [D] Like a ballpoint pen? [E] Yes, exactly. There's a sphere tip, there's a flat tip. Depending what effect you want to get out of the part, you might want
to use different end effectors. [D] Different radii as well. If it's a sharp crease, different...
Okay. [E] But that detects the smallest
feature that you can do. We've done a quarter-an-inch diameter
or some very fine detail feature. I think these are what? Half quarters?
Three-quarters? Three-quarters-in-inch diameter?
Yeah. This one is just... I can't predict where it's going. Mark, you have a complicated program. Yeah, it's rolling along the
pointing axis, I'll say. [M] You can see at the corners where it changes wall angle where
the tip goes in and out. [D] At the corners, it changes?
[M] Yeah. Right here at the bottom of the part, you'll see it comes out now
and then it'll go back in. [D] Oh, so I see. We're moving in the Z. [M] Yeah, this wall is steeper than this wall,
and now it gets steeper again. The tip goes in and out there to basically keep the tips perpendicular to
the surface that you're forming. [D] I see. Even
though it looks like it's a 2D operation on any one slice, it's actually a
3D operation the whole way around. [M] They're planar slices, but the tips move like this, depending on the
wall angle that you're forming. [D] Oh, really? [M] We have some fancy
non-planer slices too, if you want to talk about that. [E] Let me show you some of the
parts too that are non-planer. You're forming on a curved section.
Now. You're not starting from a flat sheath, you're forming from a section
that's already have forming in it. Now your robot is actually going into a
non-planer surface to deform and make. Another feature out of it.
[D] Oh, that's awesome. This is what's.
Going to happen? [M] Yeah, we're doing the face and then this triangle is the one that's just
started over there right now. This whole thing is about 90 minutes. Then it'll do this hexagon part. This one's actually a
spiral rather than layers. There's no...
[D] I feel the oil. [M] It's a 1 millimeter pitch, but
it's just a spiral the whole way. Then all of these are actually chained
together as a single operation. The robots will do one and they'll immediately go over and
start the next one without. Slowing down or something. [D] That's interesting because when I looked
at it on the internet, I thought you were going to do one plane and then just move
in the Z-axis and do more and more planes. But you don't have to do that. [M] We can do whatever we can imagine. Right here, there's a bit of a seam, if you look really closely,
where we transition. But if I do a spiral, then you
won't find that on this part. [D] You transition, meaning you move up. [M] This one is just planer slices. You do one loop and then you step
in and you do the next loop. [D] Oh, I see.
[M] The other one there is pathed as a spiral. It's just a continuous going a.
Little bit deeper. [D] Is it also faster? [M] I guess a little bit because
you don't have to turn around. Yeah, that one, it just
goes the whole way. [D] Can you tell me about
the end effector here? This is an earlier version, right? [E] Yeah, so the.. [D] Can I stand here?
[E] Yeah, of course. The goal is really what we want to do is even though we are doing sheet forming,
really our long-term goal is to build what we call a robotic craftsman, a
system that works like a craftsman. You can pick up a forming tool, form it,
drop the forming tool, pick up a scanner, scan it, drop the scanner,
pick up a trimming tool. You can see there's a spinel there. [D] Is that an ER-20 or something?
[E] Yeah. The idea is you can easily change it. You can see a tool changer here that can drop a tool, pick up another tool, and
just move on to the next operation. That's the we're imagining these robots really working like a craftsman that can
pick up tools and do different things. [D] Okay, so you're not pushing like, Oh, you're applying electrical contacts,
and then you have the mill here. [E] Yeah. Once you pick up, it automatically
connects through the electrical contacts. Now the robot now has the
milling end effector. They can drop this, pick up the forming
in the factor, go back to forming. [D] You have indexing pins to align it,
and you also align on the plane. You have total indexing. Then what's going on here? [E] Those are actually the bearings that through air pressure,
they lock into the tool. Once it picks up the slave, this thing
basically, through air pressure, come out and then lock into the tool
so the tool will not fall out. [D] Oh That's amazing. What is this? You told me, but I forgot.
[E] There are different connects. These are pneumatic connections and
these are electrical connections. [D] Got it. [E] Right now, we do mostly
forming and trimming. We do mechanical trimming. You can see that tool is in a spindle that allows us to cut the
parts after we form them. Then you have different versions
of the forming end effector. That one doesn't have the final
end effector that goes into it. It does the forming. The one next to it, it does.
[D] This one. [E] You can see that the end effector
is right in there. [D] Your tools, are they carbide
or is that too brittle? [E] We tried a bunch of material. Right now, most of our tools
are the base of it is carbide. But then on top of it, we have a coating. That coating is slightly more complicated. We have tried a bunch of different things.
[D] That's proprietary? [E] Yes. That's a coating that basically allows us
to do many parts form many parts without basically destroying the
part or destroying the tool. [D] It's a pretty simple tool, isn't it?
[E] Yes. That's the end effector is pretty simple. This is one of our designs. We have multiple designs. This is one of the design that
we're working at the moment. [B] Then the coating, getting to that. [D] That's the secret sauce? [B] -that's-it took a while.
It. Took a while. 7:00 PM, running to UPS, get this out.
[Destin laughing] [E] Even though that's a secret sauce, it really also comes down
to the software pieces. For example, if you say get the robots and run them in just get the geometry, slice
it in water lines and start forming it, the final part is going to be inches off
of what you actually want. [D] Really? [E] You have to really account for
a lot of different things. We talked a little bit about deflection of
the sheet, spring back of the geometry itself, and then the fact
that it can also tear. If you don't have the right amount of compression force between
the tips, you might tear the sheet. We get to the fracture limit
and we tear the sheet. Combination of all those things are
accounted in our software to get you a part that's going to be very close to
your final geometry and not inches off. That's, I think, where the real
secret sauce is, the software piece. [D] When you get done with this thing, you're
going to have a fully formed sheet. This is going to be a hood for a truck. It'll be done.
How do you get it, out of that?
Do you jigsaw it out? [E] The same robot, after it's forming it, scans it, and
then maps the scan to the trimming path. It aligns the trimming path to the scan the best way, picks up a trimming
end effector and trims the part out. You leave few tabs around the part and then technicians come in and cut
the few tabs and take it out. But we want to make sure the robot at
least does the accurate cutting so that the part is.. [D] Before you remove it. [E] Before you remove it. Then you leave few tabs in and then you
cut those tabs and clean those tabs up. [D] If you had titanium,
back in the day when they were building the SR-71, they didn't
know how to work titanium. I saw the glimmer in
your eye. [E] To this day, I don't think
they can easily work titanium. [D] Really? [E] I think it's just a very
tough ally to work. We figured out how to machine it,
but still forming it is very tough. Unless you elevate temperatures and room temperature is really
tough to form titanium. [D] But,
in theory. Could you use this technology to form it
and then go in and cut the rivet holes? [E] Yes.
[D] Are you very, excited about that? [E] I think those are the areas
that you're the most excited. Enabling alloys that were
just impossible before. I think, for example, for Hypersonic, you said SR-71, but all the Hypersonic
applications as the focus of attention a lot now with some of our customers,
they have a very hard time forming skin of these aircrafts out of high temperature
alloys, titanium, inconel. We're talking about refractory alloys. [D] Is this titanium?
[B] This is titanium. [E] We've already cut out the part from the customer cut out, but you can
see the rest of the sheet. It's actually a pretty thin sheet.
Super strong. [D] This is all not part of the part, but this is like the form, I don't
know what the word is. [E] We create enough stiffness around the part that as we are forming it,
the part is not buckling. [D] Got it. Okay, because I'm pushing here.
Okay, wow! That makes sense. Because if I'm pushing right here,
so steeper angles give more rigid parts. [E] Yes. The deeper it is, it
becomes rigid more rigid. [D] You just looked at me.
[B] No, I'm like... [E] That's right. The deeper it gets, also you are more
rigid because you have to overcome a little bit of elastic deformation
before you get to plastic. If you want to do a very shallow
part, it just doesn't work. You're just going to push
the part in and out. Once you go further deep,
then you create more rigidity. You can easily overcome the initial elasticity and get to
plastic regime faster. [D] My brain's on fire. The rigidity of this support skirt around the part is key, and a keen observer will
notice that in a lot of these parts laying around the shop, it's not just a flat
crease with the back plane, it's actually a wavy gusset because that's
a more rigid structure. So if I'm looking at this sheet right here, is the material the thickest it
will ever be right here in the plane? And anytime I work, I'm having to
move material, so it's going to be. Thinner here.
Is that true? [E] Yes.
I think the good law you want to apply is that conservation of
volume, right? So as you're going on a higher wall angle, the cosine of your wall angle
or sin of your draft angle times the original thickness roughly gives
you the thickness you're going to get. In the part.
[D] Ed took me to a whiteboard and he explained a complicated
Fcalled restriking. The quickest way to explain restriking is
if I want to make a hemisphere in one shot, it'll make the side walls right
around the outside diameter too thin. But if you do it in two shots, first, you make a cone and you push that cone out,
then you'll have more material, so you'll have more thickness on the
outside of the hemisphere. If you want to learn more about how this
works and a ton of different things that we didn't talk about in this video, I've
got a lot of that stuff on this second channel video where we just let the
conversation play out and you can get right into the weeds with us and
understand all these really cool concepts. It's fascinating.
Say that again. That was huge. [E] You can form parts faster than you could
simulate it on the computer, right? [D] That is such a big deal. [E] Yes. [D] A huge thanks to the folks at Machina Labs
for showing us this stuff, incremental sheet forming, or as they
call it, Roboforming. It's a really cool thing, and I'm grateful that they helped us continue the
smarter everyday manufacturing series. Speaking of which, if you are interested
in seeing the next videos in the manufacturing series,
I have an email list. I'll leave a link in the video
description or smartereveryday. Com.
There's a link to the email list there. It's really simple.
I don't spam you, I promise. Finally, I want to say thank you to
the patrons of Smarter Every Day. This is such a fun thing I get to do. It's a lot of work, and the patrons
make it possible. This community of people is the driving
force behind me hitting schedules and actually having the
resources to get it done. I'm so grateful for everybody that contributes to Smarter
Every Day on patron. If you would like to consider
that, I'd be grateful. You can check that out at absolutely no pressure here,
but it's a really cool thing. And we've had a good vibe
going over at patreon. Com/smartereveryday. If you'd like to check that
out, I'd be excited about that. Anyway, that's it. I hope you enjoyed this, the next
video in the manufacturing series. And if you want to learn more, there's more information over on the
second channel in the long video. That's it.
I'm Destin. You're getting smarter every day.
Have a good one. Bye.
