Our Services
3D CAD design, Patternmaking, Mouldmaking, White metal casting, Painting, Modelmaking
What we do?
The way we approach a clients project will always depend on what the clients needs are. However, a full bespoke model project will usually begin with a discussion on what elements are needed in the finished model i.e. static model or moving parts, all metal or are some resin printed parts allowed, scale of the finished model, whether the model will need a plinth/display case, the finish on the model, paint or various pewter finishes including blackening, polishing etc. As obvious as it sounds, this will determine the cost of the project and the lead time.
Having outlined the brief, we’ll move onto design work. This will normally begin with research – photographs, technical documents, and any other information which we can get hold of. For example, walkaround videos of the full size prototype have proven invaluable on previous projects due to the lack of available good quality photography. Research will continue throughout the design stage as CAD work begins and as more detail is added to the 3D CAD model. During the design stage the client will usually be contacted a number of times to give updates on progress.
Once the design work is completed, our design team will print any patterns and prepare these for mouldmaking. Sometimes small pipework or extra detail may need to be added here manually for a more natural appearance. This could be achieved on the computer but doing some traditional patternmaking can give a more lifelike feel to a model, especially with parts which are hanging or draped over others.
Any issues with the design which affect moulding or casting will normally have been picked up before now, at either the design stage (most likely) or the patternmaking stage using a printed ‘pilot’ model to check clearances etc. Its crucial to weed out any problematic areas at this stage before the moulds are made. After the rubber mould is vulcanised any issues will be set in stone, so to speak, and appear in the casting. Its far easier to rectify one pattern with a clearance issue than 100+ castings later. However, due to the dynamic nature of the casting process, part shrinkage or deformation can sometimes occur and may require remoulding to rectify. The casting stage is where the fruits of the teams labour really start to become apparent, boxes of fresh castings waiting for fettling, drilling and finishing give the impression of the project really beginning to pick up pace.
The modelmaking stage of the project is the part we most look forward to. As previously mentioned, updates for the client are given throughout the project, however at this stage we often email photographs of the models taking shape in the assembly line, provided this has been allowed by the client prior to the project commencement. A model quickly becomes impressive as parts are painted and assembled. Most of the modelmaking is by traditional methods, manual machines rather than CNC, hand filing where necessary, spray painting and hand applied transfers where appropriate. Depending on the model, features such as pipework may be added with small rubber tubing for example, amongst other details to really bring a model to life.
At this point in the project, any display cases or foam packaging will come into play and the models lined up and individually quality checked by our team to make certain nothing has been missed. Once satisfied, the models will be carefully boxed, often using bespoke cut foam to ensure they arrive at the client safely.
If photographs have been allowed by the client, we will photograph one or more models for our own records and the clients if necessary. If another batch of the model is needed in the future, we can use these photographs as a blueprint to build from.