Interactive model with speed and direction controls

This unusual industrial model was a real challenge on two fronts – firstly because of the very complex shaped components involved but also because of the requirement for a very specific interactive element. The thruster comprises a large propeller that forces water downwards through a deflector that can be rotated through 360 degrees to direct the water thrust in any direction. This is the USP of the client’s product and, as such, he wanted the model to incorporate a rotating propeller (with speed control) and a movable deflector (clockwise and anti-clockwise) at 6rpm. We also had to work out how to mount the model in a cut-away view of a ship’s bows and create a cut-away view of the thruster to show the main working components. The model was recently shipped in a large flight case to a trade event in Germany – one of the inset images shows it on their stand.

 Revolving Globe Display

The client for this project, Nottingham University wanted to create an eye catching icon that they could use as a marketing tool at various promotional events. To emphasize their strong overseas connections they wanted to visually portray their marketing strap line “Closing the Global Knowledge Gap” by creating a world globe made up from jigsaw shaped pieces with their logo as the final piece of the puzzle. We developed this brief from loose concept stage to a fully realized functional display that they could transport and set up easily themselves at any venue. We even threw in the idea of making the globe rotate slowly and up-lighting it from below to add extra visual impact. The globe itself was made from fiberglass (for strength and lightness) with a painted and lacquered finish.

River Bed Model in Fibreglass – Horizontal Scale 1:125,000, Vertical Scale 1:125

Commissioned by Cardiff University’s Engineering Department, this 6 metre x 4 metre fibreglass model of the River Severn Estuary and Bristol Channel river beds was a very technically demanding job, not just because of the huge volume of complex data involved but also because of the sheer size of the project. Comprising several large sections that bolted together, it had to be an accurate representation of the riverbed contours (at an exaggerated vertical scale) because it was being used for physical experimentation in a major research program on tidal power generation.

How we made it

The first stage was to create a “mirrored” negative (upside down and back to front) version of the river bed contours all the way from Gloucester, down the Bristol Channel as far as the open sea. This comprised six major sections and several smaller, infill sections. These contours were made from laser cut acrylic layers supported on an MDF substructure, all fixed onto a structural base board with upstanding sidewalls. To construct the accurate depths and contours we had to create our own CAD masterplan using a combination of traditional Admiralty Charts, CAD contour maps, reams of numbers giving spot depths, and numerous sections through the river bed at key areas.

Once the basic structures of the moulds were built, the contours then had to be blended into a smooth continuous “land-form” using various filling techniques. At the same time great care had to be taken to ensure the contours matched perfectly across the joins between the sections. The contours then had to be sealed and “polished” to a fine finish so that the fiberglass forms would come away cleanly from the moulds once they had cured.

The final stage was to layer up resin and fiberglass matting into the moulds, starting with the “gelcoat” layer (which is in effect the top layer and is the visible finished colour) and then several more layers of resin and matting to build up the structural integrity. The fibreglass sections were then eased out of the moulds and flipped the right way up, ready to be joined together on to a structural sub-frame which supported them all at the right height. The image shows the sections just after they have come out of the moulds. They had been loosely assembled on the floor to check for fit.

Interactive industrial model at 1:250 scale

When the guys at DHL (UK) spotted we’d made models for both UK Mail and Hermes they knew we were the right company to supply a high quality model of their brand new southern depot at Poyle, near Windsor. Like the UK Mail and Hermes models, this needed to be a “roof-off” view of the building showing the huge investment in sophisticated sorting machinery within the new depot. DHL actually went a step further and asked us to make the model interactive so that ten specific areas of the machinery could be illuminated individually at the touch of a button (you can see the buttons in the main pic above). The most difficult part of this project was deciphering the CAD info for the machinery and then modelling the complex industrial components to a slightly simplified but recognisable level. We then had to work out how to build in the LEDs so that only the relevant areas lit up. All in all, it was a very technically demanding brief but DHL were very clear what they wanted and we delivered!

Two 1:400 scale models of parcel handling depot

UK Mail ordered two identical site models of their huge new facility at Ryton because they needed an overview model at either end of the site, one in the offices and one in the main warehouse building. Constructing two models at the same time enabled us to offer them a significant saving on the second unit. 1:400 scale is a good option for a site model because it keeps the base size down but still allows us to show a recognisable level of detail. We were even able to show a good representation of the parcel handling conveyors through the cut-away roof (click on the inset pic above to see the detail).

 White styled model of proposed college buildings

This white styled model was used to illustrate a proposed design for a new college. The white styling was chosen deliberately so as not to be too specific about material finishes – these were to be finalized at a later date. 1:400 is quite a small scale but it is ideal for a site model because it allows us to show a wide overall area on a fairly compact base. And if you click on the images to enlarge them you’ll see that, despite the small scale, we can still show plenty of informative detail that invites close-up inspection and therefore engages the viewer. This was one of two models that formed an overall presentation. The second model (which will be the subject of my next post) was a larger scale sectional model focussing on the building’s main architectural feature, the central Atrium.

Small Scale Housing Model – Scale 1:500

This is an unusually small scale for a housing development marketing model – 1:200 scale or 1:250 is more typical for this type of project. This small scale was chosen due to limited space and a tight budget. But although this lacks the detail of the larger scales it does convey a clear easy to understand overview of this large spread out site. The grey blocks represent existing buildings that are not part of the development. If you click on the Enlarge Image feature on the picture, you’ll see that a surprising level of detail is shown (even though the house elevations are only about 14mm high) and we’ve even created accurate topography with stepped roof levels and sloping contours, etc.

Bangor University New Building – Scale 1:400

One of the main purposes of this model was to demonstrate how this major new building addresses a complex, steeply sloping site. It was also used to illustrate the scale and massing of the new development in relation to the existing university buildings and the surrounding townscape.