Malcolm Nicholls Ltd utilised 3D printing and 3D scanning technology to reproduce and 3D print trophies – 18 replica trophies to be exact! For an Abu Dhabi HSBC Championship-associated golf tournament.
An exciting project that saw Malcolm Nicholls Ltd utilise 3D printing and 3D scanning technology to reproduce 18 3d Print trophies (replicas) for an Abu Dhabi HSBC Championship-associated golf tournament.
On the Abu Dhabi golfing circuit, the Falcon Trophy has long been synonymous with the Abu Dhabi HSBC Championship. The Pro-Am tournament serves as a supporting competition which precedes the main event. Event organisers wanted smaller versions of the Falcon Trophy to award winners of the curtain raiser tournament and briefed isodo3D about producing 18 quarter-size replicas, six for each of the next three tournaments.
Isodo3D worked along with Malcolm Nicholls Ltd when they found that the most cost-effective and non-compromising method was to print the falcon and golf ball and then hand turn the wooden plinths. A HP 3D Structured Light Scanner Pro S3 was used to scan the trophy and create the data required to print the trophy. Using our latest SLA technology a master model was printed.
With the growing demand for Low Volume Production also known as low volume manufacturing and small batch production Malcolm Nicholls Ltd can produce 1 – 1000’s of parts.
If you’re looking for a one-off bespoke top-quality part such as a trophy, or you require 1000’s customised parts such as widgets, we have the solutions to suit your needs.
It is an increasingly popular option as it allows for a smaller investment in tooling and materials while providing fast access to the market. It also acts to bridge the gap between initial prototypes and mass production.
Historically, manufacturing components in low quantities has always been a costly exercise. With the advent of 3D printing and vacuum casting many constraints previously faced can now be significantly reduced. Technologies such as SLS (Stereolithography) and FDM (Fused Deposition Modelling) can now be used (especially for non-seen parts), to produce components in quantities as low as 1s and 2s and up to thousands, but still with exceptional material properties such as flame retardancy and high-heat requirements. Traditional design constraints, usually associated with injection mould tooling for example, can now be ignored enabling designers to be more efficient and reduce part count within assemblies.
We can produce anything from one to thousands
When approached by a leading supplier of machines that produce canning/food machinery, we were asked to produce a 3D printed exhibition model not only to produce a scale model of a machine but to also make it semi-function. The Third-Scale model was to represent a 4-metre long canning machine. It was to be able to demonstrate the unique selling points of the machine at a forthcoming trade show in Europe. With so many moving parts, the accuracy of the process and model were imperative.
The primary stage for MNL was to work on the 3D CAD data, when you scale a model down to such a small scale factor some elements can be lost – made so small they disappear, these would then need to be scaled at a different factor. Even simple nuts and bolts had to be re-drawn. As an example, a half-inch thread at 1/3 scale becomes 1/6th inch. this had to be altered to the nearest metric equivalent to prevent the necessity of producing non-standard bolts. Over 200 man-hours were spent working with the CAD, MNL wanted to ensure that what was produced or rectified was correct so many 3D PFS was created to show the end customer the design intent. As many sub-assemblies were to operate (albeit manually), once again MNL turned to the CAD to communicate with the customer, illustrating which assemblies moved, and be what extent. Animated movies were produced and sent to the customer to once again demonstrate the intended movements of the model.
Once 3D data was approved the manufacturing processes started. Many larger components were CNC machined from ABS for accuracy, strength and durability. Some components were produced via SLS, whilst the rubber items were made from silicon tooling. The chain was made in one assembly by connex machinery.
Vibrant colours were used to draw attention to the model at the trade show. The different colours illustrated the various areas and USPs of the design and function of the machine. MNL suggested having the sides of the model in clear acrylic to show internal components and how they function.
Once the model was completed a purpose-built plinth and flight case were produced so the model could be shipped worldwide without the worry of it getting damaged. Then to finally finish the model a Perspex cover was produced.
Malcolm Nicholls Limited (MNL) loves a challenge. For this project a 3D printed Stereolithography (SLA) model was produced. These 3D printed models were given to MNL’s finishing department where the build lines were removed and worked until a smooth surface finish was achieved.
Theses printed parts were to be used as master patterns for MNL’s soft tooling (silicone tooling). Once tooling was completed MNL cast the end products in a highly durable material, also colour matched to the customers supplied pantone reference. Maximum castings from this tool for a rigid material were 20 castings.
The handle also had a clear window produced in the exact same way but the level of initial finish was a perfect high gloss due to needing a water clear casting. This window was to be used for advertising.
We produced oversized 3D printed stars for Mugler Perfumes retail display
Thierry Mugler Luxury Perfume was established in 1973, the Paris-based fashion brand is redefining its retail presence by consolidating its fragrance lines under a single brand name and logo. A notable addition to Thierry Mugler’s retail identity is the stunning Thierry Mugler Angel Star, featuring sculpted facets designed to play with light and shadows.
As a leading name in 3D printing for luxury brands, we played a pivotal role in this transformation. Employing Stereolithography (SLA), we crafted an oversized 3D printed ‘master model’ for the Angel Star, utilizing a process renowned for its exceptional surface finish.
Our finishing department meticulously achieved a perfect gloss on the 3D printed model, essential for the subsequent metalizing coat application, which imparts a high shine chrome effect. These 3D printed models are created with precision. The 3d Printed retail displays now serve as captivating point-of-sale displays for Thierry Mugler’s luxury brand, seamlessly blending innovation with retail aesthetics.
We can produce anything from one to thousands
For most of the clear components, these were 3D printed using MNL’s Stereography (SLA) 3D print large frame machines. Once built each clear component was hand finished by MNL’s highly skilled models makers to a perfect high gloss. These were then used as patterns for MNL’s soft tooling to yield water clear castings.
Other processes used were Selective laser Sintered (SLS) masters in a PA Nylon, again hand finished to that perfect gloss.
It has been said that MNL prototypes look better than production parts as the component will have no evidence of mass manufacture. All of the processes used were durable so that they could be used in there correct environment, also letting the end customer see their vision come to life in a very short timeframe.
Graphics were applied to the finished prototypes to give it a more realistic look.
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