Rapid Prototyping Examples.
This page shows a range of rapid prototypes and small production runs that didn’t have a brief, just a quick problem to solve. They mainly feature the use of a 3D printer to make brackets, bespoke parts and quick fixes
Cable Management Clips.
Creating a small production run of cable management clips for a tubular metal table system without the need for any tooling investment. A range of materials and print settings were tested to find the right structural integrity, whilst still allowing the clip to flex and snap onto the tubular metal frame.
EPS 1:1 Models
We needed a way to test and prove a sit on a high investment ply pressing, without committing to the tooling initally. using the inner face of the ply, it was turned into a Expanded polystyrene form than could take the weight of a person to check the geometry and test various foam grades before committing to to the ply tooling and cold cured foam moulds.
Seat Pan Stacking Buffers.
Whilst working alongside an external designer, it became apparent we needed a stacking buffer to ensure the upholstery would not face degradation from compression over time. After a quick call to establish the needs with the external designer, a CAD file was sent over. Whilst waiting for the supply chain to return quotes, I quickly loaded the file into the printer with a few tweaks so it could be printed and created a quick prototype. The fit and tolerances of the pan were tight and it meant I could relay subtle tweaks before investing in any tooling.
Rotating Mechanism Spacers
A client needed replacement spacers for a tabling system, which was discontinued about five years ago. Our existing supplier based in the far east, would only provide a minimum order quantity of 1000. The clients tables required only 40 and needed them by the end of the week. The only reference available was the metal bracket it pairs with and a different component that fitted in a similar manner. By taking the critical dimensions and reviewing old marketing images of the product, the use case and technical requirements were pieced together. Within a few hours and a couple of lower quality prints, the form was established. After that, it was down to refining the printing settings and letting it run overnight to come back in the next day to a print tray of 44 parts.
Ply Pressing Mock Ups
Created to test the fitment and suitability of the mechanical fixings, when a full pressing wasn’t available. These two 3d prints perfectly replicate the outer shell of a ply pressing and allowed a machined prototype to be test fit before committing to tooling for the ply pressing and High pressure die cast arm and rail system.
The testing proved the M5 bolts would not locate correctly and needed the ability to account for manufacturing tolerances. It also brought to the conversation the need to preserve key feature during the finishing process and the need to document and create buffing guards to ensure clean edges when fitting together.