2022 Timberline Controller

The 2022 Timberline controller consists of 3-mm tempered glass adhered via VHB to a plastic chassis. The controller utilizes cap-touch and has numerous elements to get the correct lighting effects from the light ring, including deadfronting, masking, and a light pipe. This was by far the most challenging and complex project I completed. I've included some pictures of the development and testing process as well.

Overall Rendering

The screen sat flush with the hopper face at a 30-degree angle, making it easier for the user to see. The interface was water-tight. I've highlighted a select few parts below that I designed & owned, although this assembly contained more. I designed part of the hopper wrap, see more info here.

Assembly View

The controller is found in all 2022 Timberline grills, elevating the level of quality for all Traeger owners to come.

Faceplate (V1)

This is the original housing for the controller, roughly 10"x4". This piece proved to be the most problematic due to an incongruency in cooling rates in the mold that was not caught in the mold flow analysis.

Faceplate (V2) + LSR gasket

After the light ring was separated out, the faceplate was altered as well to remove the problematic geometry. I designed an overmolded LSR gasket as well that was very buoyant and could absorb large tolerances in the mating features if necessary, avoiding stress on the controller.

Light Ring

This component was not in the original design. It was a late change due to the plastic cooling issues mentioned above. It solved the problem and allowed for more uniform strain distribution throughout the part during the molding process.

Controller Knob

This high-quality knob was made via machining, knurling, and anodizing with laser etching. I worked closely with the manufacturer and ID to find a knurling pattern that provided a pronounced yet comfortable grip.

Knob Insert

This insert was a press-fit onto both the encoder and the knob (above). The spline matched with the encoder spline to provide a robust grip on the encoder, meeting a predetermined "pull force" specification.

Knob Boss

Due to limitations of the light ring geometry, this piece needed to be separate due to the annular ribs. It would have been impossible to tool up if combined with the large chassis, due to the need for both pulling action and side-action that would interfere.

Thermotron Testing

Traeger tests all electronics in high-low thermal cycle tests to make sure that the components are not affected by climate swings. This controller in particular had issues at high temperatures in early design iterations.

Light Ring/Display Testing

To get the light ring looking snazzy, I had to combine a number of elements: a light pipe, white resin, LED isolators, and specific geometry to protect against light bleed. The display screen utilized deadfronting and masking behind the glass as well.