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.

Market Sector: FDM - 3D Printing | Featured Case Study | Jigs and Fixtures | MOD | Rapid Prototypes or 3D Printed Models

FDM - 3D Printing | Featured Case Study | Jigs and Fixtures | MOD | Rapid Prototypes or 3D Printed Models

Printed using fused deposition modelling (FDM) in a high temperature material (ULTEM) this model was for reference prior to CNC of a vacuum forming tool. Due to the loose layering on an FDM model air can still be pulled through making this a perfect process to vacuum form over Thermoforming. Thermoforming is the collection of manufacturing methods that heat and form sheets of extruded plastic. It is a relatively simple process that starts with heating a plastic sheet to a pliable state. Once softened, the sheet is forced against a mould with the desired shape using different methods: In vacuum forming, a vacuum is drawn through tiny holes in the mould. In pressure forming, air pressure is applied to the surface.

The word biscuit comes from the French for twice cooked.

When approached by a leading creative packaging manufacturer Malcolm Nicholls Limited (MNL) were tasked to produce a series of Vinnie biscuit containers. From supplied 3D CAD (STL File), 3D printed models were produced. Using MNL’s Stereolithography (SLA 5000) models were produced in a matter of hours. Once models were produce they were given to MNL’s final finishing department to work their magic and give the models that perfect surface finish with both matt and satin. Once surface finishing was completed these models were to be used as patterns for MNL’s soft tooling – (Silicone tooling), a series of casting were produced in a durable polyurethane material that emulates ABS. These prototypes were to be used to trial packaging runs prior to hard tooling being available.

MNL’s customer produced a novelty shaped tin for the Fox’s biscuit brand Vinnie’s Biscwits Selection range. The new container’s shape follows the contours of the Vinnie character’s head and is designed to capture consumer attention in the retail aisles.

The brand’s iconic mascot Vinnie, also known as the Chief Biscwit Officer, is featured prominently so that the container will instantly register with prospective customers. The matte varnished design features Vinnie munching on a golden crunch biscuit filled with vanilla cream, set against a metallic purple background finish.

Printed using fused deposition modeling fdm – FDM Printing in a high-temperature material (ULTEM) this model was for reference prior to CNC of a vacuum forming tool. Due to the loose layering on an FDM model air can still be pulled through making this a perfect process to vacuum form over Thermoforming.

Thermoforming is the collection of manufacturing methods that heat and form sheets of extruded plastic. It is a relatively simple process that starts with heating a plastic sheet to a pliable state. Once softened, the sheet is forced against a mould with the desired shape using different methods: In vacuum forming, a vacuum is drawn through tiny holes in the mould. In pressure forming, air pressure is applied to the surface.

What is FDM Printing or Fused Deposition Modeling FDM?

Crank it Up

Triumph Motorcycles utilise MNL to create their prototype components. One such component was a crankcase housing for one of Triumph’s engines.

The crankcase, measuring 550 x 290 x 150 mm, was created in one build on our SLA500/40 Stereolithography machine.

MNL has developed its own “RNW” stereolithography build style which more than halved the predicted build time, down from 50 to less than 24 hours. This gives way to shorter lead times and reduced costs.

The 3.1 Kg SLA was used for design evaluation, fit & function tests, and also as an invaluable toolmakers aid. Further design iterations were incorporated, leading to other SL models being made as foundry patterns for prototype castings.

MNL constantly strive to increase their competitiveness, as shown here by producing faster build styles.

First Utility, a newcomer to the energy supply market, wanted a unique approach to the mainstream advertising of energy. First Utility decided to move away from the ads of their competitors and with a tongue in cheek spot that see’s the brand launch a mock energy company – HD Electricity, which captures the amazing power of unicorn horns – to hammer home the message that all electricity does the same so people shouldn’t pay more.

The carmargue horse was to be used as a photography model wearing a mock unicorn horn. The artistic director wanted the look of the horn to be similar to that of a narwhal horn. As these are hard to come by especially in the sizes required for the shoot, models were commissioned.

Malcolm Nicholls Limited (MNL) produced CAD models of the organic shape from visuals supplied by the client. The visuals were used as a basis upon which to base the “design” upon. Upon approval of the CAD, SLA models were printed, and all evidence of any layering removed. They were then painted white as a blank canvas for the application of the natural browns and other colours that were airbrushed on to give the totally natural look.

By the way; a group of unicorns is called a blessing!