From concept to the big screen
The film technology company ARRI needed a technically sophisticated connector for the image sensor of its new ALEXA 35 digital camera system. EMC developed this complex connector—and we’ll tell the story from the initial idea to its use on film sets around the world.
1 – The Beginning
It’s all about image quality
2015. Image resolution has become a crucial factor. The brilliance of a photo or film, and the sharpness of a live broadcast, captivate viewers—the higher the resolution, the better. And the higher the ratings, the greater the revenue. These considerations also drive the requirements of the internationally active film technology company ARRI in Munich. For the production of a new digital camera system, a connector is needed that ensures the transmission of extremely high data volumes.
At embedded world, a major electronics trade show in Nuremberg, manufacturer ARRI and the potential supplier of the base, EMC, will meet for the first time in the spring of 2015.
2 – The Concept
But can you build the high-performance socket?
Because the version being developed will be only a few centimeters in size, the requirements are highly complex. The socket must contain 847 precisely positioned contacts through which information will later be transmitted seamlessly in a matter of milliseconds. One of the many challenges: On the one hand, the image sensor must be securely seated in the socket—only then can it function optimally and guarantee outstanding image quality—while on the other hand, it must be able to be easily inserted into and removed from the socket. At the end of the selection process, ARRI chooses EMC. Exciting years lie ahead.
Of course, it was an advantage that our development partners were in the same time zone. But we could have pulled it off as a global collaboration as well
3 – Development means:
Go the extra mile, be patient, find solutions
Now things are getting serious. Development work is underway. EMC has a partner in Switzerland who will manufacture the product. Countless rounds of coordination lie ahead. In Idstein, the team is designing, planning, and drafting. In Switzerland, the product is being built, and Munich provides feedback. And then it starts all over again. For a key component—the pin, consisting of a sleeve and a contact spring—there is no prototype; it must be created, so to speak, from scratch.
I think people really appreciated that we were always open to trying new approaches!
4 – The Prototype
Test, Try, Error, Test
Then the first prototype arrives. ARRI tests it and defines new requirements. For example, in the final product, cables must be routed to the sensor through the base. This, in turn, affects the stability of the base. Further development, production, testing, and rejection follow… New problems arise: To prevent circuit boards with faulty sensors from being discarded, the image sensor is designed to be plugged in and unplugged like a connector. During initial tests, the plug contacts come loose. Back to the drawing board.
Such processes are always characterized by the fact that you learn as you go. Slumps are normal
5 – Production and a Shock
The world has come to a standstill
2019. Go! The final version has been finalized. The order is to produce larger quantities. The machines are running, and a whole batch of plug sockets is ready for installation. Then a virus brings the world to a standstill—COVID-19 not only disrupts supply chains but also rocks the entire film industry. Live events are no longer taking place. Rien ne va plus. Film cameras aren’t even arriving, and later on, they’re only being used on film sets with very strict hygiene measures. Great disappointment on all sides.
When you invest so much—including your heart and soul—it’s only natural to feel disappointed in the face of such an unpredictable crisis
6 – The Turning Point and the Fresh Start
Things are moving quickly now
2022. The fear of the pandemic is subsiding. The film industry, particularly streaming services, is emerging as the winner of the global crisis. Now everything has to move very quickly. Fortunately, a fully developed, smart solution is ready to go. ARRI is introducing its new digital camera system to the world: ALEXA 35. Inside this coveted high-tech device: the EMC Super Base. Demand for cameras with outstanding image quality is high.
Of course, everyone is really excited. But ARRI never doubted for a moment that we’d pull it off in the end
7 – The final chapter of this success story isn’t the end
The Super Base Is Making a Name for Itself Worldwide
Today. The contact socket developed by EMC is making a name for itself with the ARRI ALEXA 35. It is currently being used on prestigious feature film and TV series projects being produced all over the world. The results are increasingly appearing on the big screen and on home screens. And behind the scenes, the EMC product has always played its part in ensuring their success.
The big advantage of this product is that you no longer have to throw away the circuit board if the image sensor is defective. It plugs in and out just like a battery! It’s a small part that we sell, but it’s a very important one.
Production continues in series. This is just one of many success stories that the Idstein-based company has achieved thanks to its experience and expertise. Connections. Since. 1991.