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The making of Andy Rubin's 'Essential' phone

Essential, led by Android's co-creator, used its very own machine shop to help develop the phone, fast.

Jessica Dolcourt
Jessica Dolcourt is a passionate content strategist and veteran leader of CNET coverage. As Senior Director of Commerce & Content Operations, she leads a number of teams, including Commerce, How-To and Performance Optimization. Her CNET career began in 2006, testing desktop and mobile software for Download.com and CNET, including the first iPhone and Android apps and operating systems. She continued to review, report on and write a wide range of commentary and analysis on all things phones, with an emphasis on iPhone and Samsung. Jessica was one of the first people in the world to test, review and report on foldable phones and 5G wireless speeds. Jessica began leading CNET's How-To section for tips and FAQs in 2019, guiding coverage of topics ranging from personal finance to phones and home. She holds an MA with Distinction from the University of Warwick (UK).
Jessica Dolcourt
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1 of 21 Josh Miller/CNET

Here's how the Essential Phone was made

The Essential Phone is a newcomer with lofty ambitions: To help make modular phones robust and coveted. 

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2 of 21 Josh Miller/CNET

Part of a larger project by Andy Rubin, who's widely known as the father of Android, the Essential Phone was fine tuned in a machine shop that's part of the company.

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3 of 21 Josh Miller/CNET

This is the machine shop where Essential's team made their own prototypes -- it's faster than farming it out and less prone to leaks.

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4 of 21 Josh Miller/CNET

Shells like these helped the company's engineers tweak everything from color to the way the components fit. 

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5 of 21 Josh Miller/CNET

The Essential Phone has a titanium chassis, so Essential built test models from titanium slabs using an industrial 3D printer.

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6 of 21 Josh Miller/CNET

It may not look like much from the outside, but the 3D Systems ProX 350 uses a laser to melt layers of fine titanium powder that's spread over the plate.

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7 of 21 Josh Miller/CNET

It takes about a day to print the body of an Essential phone.

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8 of 21 Josh Miller/CNET

Titanium 3D printing can get very detailed.

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Essential's machine shop also has a 3D printer for making plastic mockups... 

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For example: These 360-degree cameras, which (in their finished form) magnetically snap on to the Essential Phone.

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They also use a milling machine to prototype parts like the magnetic connector that attaches the 360-degree camera to the phone.

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12 of 21 Josh Miller/CNET

Get a load of those metal shavings.

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They can also machine parts out of plastic and glass, which won't create dangerous sparks.

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14 of 21 Josh Miller/CNET

Unlike the first one, this milling machine has 60 tools it can pull from, and the work table in the center moves on its axis while others remain static.

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Many of the machines in the shop cost half a million dollars each, said Rick Becker, the machinist.

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16 of 21 Josh Miller/CNET

Essential made these mockups in-house to precisely tweak the fit of the magnetic connectors.

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17 of 21 Josh Miller/CNET

Essential isn't shy about sharing the missteps that went into the process of making its first phone.

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A rack of body designs.

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19 of 21 Josh Miller/CNET

Essential isn't the only company to use the machine shop. It shares space -- and prototyping priority -- with other companies that are part of Rubin's product accelerator, Playground Global.

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20 of 21 Josh Miller/CNET

One last look at the Essential Phone etched into the titanium slab before being printed into a 3D metal model.

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21 of 21 Josh Miller/CNET

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Go hands-on and dive deeper into the Essential Phone with us. 

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