gallery download order support links contact wekker.gif
DeskProto
go to the homepageview the sitemapsearch this siteview this page in printer friendly format
design bureaux modelmakers jewelry arts ceramics consumer goods education / universities food and sweets medical packaging research institutions scale model manufacturers signmakers (rapid) toolmakers transportation (cars, trains, planes,...) various applications world map of DeskProto users
 

GALLERY

A simple mould for small series production


The Swiss manufacturer of large fair-attractions Giovanola had a new Roller-Coaster designed by the Swiss design bureau iDE. The design of the housing of each 'cart' has been created using the Alias (tm) CAD-system, which is a very good tool for freeform designs like in the automotive industry.

The production of the housing (small series) will be done by hand using polyester layup methods, so a mould is needed. This mould should of course exactly match the CAD-design, asking for a Computer Aided route to create it. This is where DeskProto comes in: the Dutch model maker Joop Aarts calls us for assistance.

Alias software
Left: A screen-view of the Alias (tm) software showing the design

Right: DeskProto window showing the STL-file.
STL-file

Joop Aarts wants to create a negative mould (hollow), and needs a positive model in foam to create it (by casting the mould around the model). Four moulds are needed: for the first cart the bottom shell and both side-shells (different for left and right), and for all other carts the side shell. The geometry is shipped from Switzerland on diskette in the form of STL files (Alias can directly export these).

In DeskProto the STL-files are read, the geometry is correctly rotated, and NC toolpaths are calculated. These are sent out for milling to a third party (as the available desktop CNC milling machine is far too small): the Dutch moldmaker Jadima. As the illustration below shows, Jadima's milling machine in fact is not large enough too, however by milling some separate segments after one another it works out fine. The models are milled in PUR foam (quite roughly), and further finished by Joop Aarts.

NC toolpath
Left: DeskProto window showing part of the NC toolpath (the first layer)

Right: The actual milling of the prototype, on a three axis Deckel machine (dimensions ca 1,200 x 700 x 450 mm)
milling process

References:
Manufacturer of the Roller-Coaster:
Giovanola Freres S.A. in Monthey, Switzerland

Design of the Roller-Coaster:
Innovative Design Engineering (IDE) in Belmont, Switserland
Creation of the production moulds:
Joop Aarts Design in Beek en Donk, the Netherlands

Calculation of the NC milling paths:
Delft Spline Systems in Utrecht, the Netherlands

NC milling operation:
Jadima Fijnmetaalbewerking bv in Ede, the Netherlands.

roller-coaster closeup shells
The resulting Roller-Coaster, in which the side-shells of the first two carts can be recognized. (the others are not present yet on this photo)
A close-up of the first two side-shells