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
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.
MNL were supplied with completed 3D files (in this instance a STL file), enabling MNL to 3D Print using Stereolithography (SLA).
Once initial printed components were built these were then given to MNL’s highly skilled model makers to give it that perfect glasslike finish.
Using these finished masters MNL was able to produce sets of silicone tools. Despite the complex nature of certain areas of the design of the component, the silicone tool was able to be cut and flexed open to enable the mouldings to be released where the complex undercuts existed.
Castings from these tools were produced in a water clear resin that emulates clear Perspex. Many sets were cast in only a matter of days, reducing that all important timeframe of concept through to market.
For more than fifty years the Kenwood Chef has been a lifesaver in the kitchen – more than 10 million have been sold worldwide. The Kenwood Chef builds on this distinguished heritage and cannot be beaten for functionality, innovation, performance, speed or design. The art of family cooking can again become a pleasurable experience. Getting the balance of ingredients correct in any recipe is vital to ensure the correct blend of taste and texture for your final dish. When producing a model to represent a new design for Kenwood’s “Chef” food mixer/processor, a delicate balance of processes that Malcolm Nicholls Limited (MNL) had to offer had to be chosen.
The model needed to satisfy various functions. Firstly the visual appearance had to be exactly as per the design offices intent. The intention was for the Chef to be predominantly stainless steel, with various finishes, including bright chrome-work, matt sections, and other components with a brushed look. Prototyping stainless components are costly and time-consuming, the method required to produce the model to represent these finishes, had to overcome these hurdles.
Secondly the model was to be semi-functional only; as there would be some more market research carried out using the model for public perception on the look of the product. The model should demonstrate how the top half of the Chef could be raised, how attachments could be fitted, and how the mixing bowl could be removed etc. Another one of the models’ functions was to aid the marketing department with photographic shots being taken for posters, exhibitions and possible press launches.
Despite the fact that the model was not to be made from stainless steel, it still needed to be durable enough to withstand the rigours of excited engineers. The model might also be needed to face the public’s scrutiny, and it is those whom may not appreciate the strengths and weaknesses of physical models.
With all these considerations in mind, as well as the usual budgetary constraints, MNL decided to construct the model Chef over a solid lightweight model-board chassis. The underside of the top section was CNC machined from solid aluminium to stop the top section from drooping under the weight of some of the attachments (standard production attachments for the Chef range). The chrome components were cast in polyurethane (PU) resin from silicone rubber tools, produced from Stereolithography (SLA) masters. These PU castings were then vacuum-metalized to give a near perfect match to the real thing. All other visible components were produced as SLA parts, hand finished and then sprayed to the required colour and texture. The excellent combination of MNL’s model-makers and the superb durability of Somos 9120 SL resin. Combining the skills of their hands-on model-makers with the latest available 3D printing technologies and materials, MNL had all the ingredients needed.
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