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IDC Models Brings Alive Red Bull’s Dream Racing Car

IDC Models, the rapid prototyping and model making division of Industrial Design Consultancy (IDC), has just completed a prototype of a radical new concept race car, which comes straight from the mind of one of the world’s top F1 car designers, Adrian Newey, Red Bull Racing’s Chief Technical Officer.

The project has a top pedigree, with the concept car ultimately starring in GT5, the latest release of Gran Turismo - Sony PlayStation’s legendary game launched on November 24th. The concept car has been designed by Newey without the usual restrictions of race regulations. This enabled him to have a blank canvas and put all his technical energy into a design that pushes the boundaries of motorsport, with a shape and form that makes history.

With such high profile interest, the project has been conducted in secrecy over the last six weeks. Using data supplied to IDC Models straight from Polyphony (the GT5 game developers) the model has been assembled in sections to its full size of 4.75 metres long by 2.2 metres wide. Each model section was CNC machined and then fitted together and finished to give a seamless surface finish. IDC Models was selected for its outstanding model making reputation, combined with its facilities and flexibility. IDC is one of only a few rapid prototyping bureaus in the UK with large-scale CNC facilities.

“Building this model was a fantastic challenge in so many ways. To build a car of this size and detail from scratch in just four weeks required all our model making techniques and rapid prototyping technologies,” says Head of IDC Models, Vincent O’Horo. “After all the long hours and intense effort, the whole team is immensely proud of this amazing achievement and our involvement in such an exciting project for Red Bull.”

The modelling project has been documented by time-lapse photography; showing piece-by-piece how the Concept car prototype has taken shape to its landmark final form. This is available for viewing at: www.idcmodels.com.

The concept car design has already been put to the test by Red Bull Racing F1 star, Sebastian Vettel. He took a seat as a virtual test driver in the Concept car prototype around Suzuka in Japan. On his first virtual lap, Vettel beat the lap record by more than 20 seconds.

“Adrian’s dream car handled brilliantly,” said virtual test driver Sebastian Vettel. “There are few tracks that reward bravery and commitment more than Suzuka and I can’t think of a better way to experience the pace and performance of the Concept car prototype than going through 130R at full throttle.”

The concept car prototype was unveiled at the Red Bull Racing/GT5 launch on November 24th.

25 November 2010

IDC Models Launches Rapid Prototypes Loyalty Scheme

IDC Models, the model making division of Industrial Design Consultancy (IDC), has just launched an exciting new client loyalty scheme, which will reward clients with an almost endless variety of gifts. Called the Rapid Rewards Club, the scheme is free to join and points can be accumulated for up to five years.

Vincent O’Horo, Production Director at IDC Models explains, “When it comes to SLA prototyping, the great majority of our customers use IDC for repeat business and we wanted to give them something back to reward their loyalty. The Rapid Rewards Club gives them an opportunity to treat themselves or their teams to anything from a gourmet dinner to skydiving, as well as practical gifts such as a MacBook or iPad.”

For every one pound the client spends on SLA rapid prototypes and models, they will receive one point, which can either be left to accumulate or redeem prizes. The Rapid Rewards Club is free and easy to join. Full details of the scheme and a gallery of rewards are online at: www.idcmodels.com.

IDC Models guarantees a quick SLA service; from their simple online quoting system, right through to product despatch, which is normally the next day. This, in combination with the Rapid Rewards Club, now brings benefits to clients in the form of both time and money.

12 October 2010

Instant iPads from IDC Models

At IDC Models we understand the importance of fast, accurate and deliverable products and services, which is why we pride ourselves on our fantastic SLA service. We also understand that it’s great to receive a little more than what you bargained for, which is why until the 30th September 2010, IDC Models is offering an iPad or an iPod touch to all customers who place an order for SLA parts. For terms and conditions go here.

Our Viper SLA system lets you choose between standard resolution mode, for the best balance of build speed and part resolution, and high resolution mode for ultra-detailed small parts and features.

Our SLA services include:

SLA stereolithography 3D Printing
Uses lasers to build high precision parts
From CAD to finished model in a matter of hours
Resin similar in properties to polycarbonate
Other finishing / spraying / assembly services also offered
Tight deadlines

It is fast and simple to receive accurate quotes, use our instant SLA quote system now hassle free and non-obligatory.

21 July 2010

IDC Models Uses Special Moulding Solution to Test Mobiles

IDC Models was tasked by IndexSar to find a solution to a difficult moulding issue. Indexsar required a model of a human hand which would incorporate carbon black to absorb the radio waves emitted by mobile phones during performance testing, but this presented several problems.

Vince O’Horo, director of IDC Models, explains, “Carbon black is a difficult substance to work with. The ratio of carbon to polymer needed to be exactly right in order to distribute the carbon evenly throughout the phantom hand. Often the black carbon powder becomes very thick when mixed making it difficult to manipulate and creating air pockets within the mould. We had to work quickly and accurately, employing a moulding technique customised for the job in hand.”

Rapid prototyping was a core part of perfecting the production process in-house at IDC Models. Polyurethene elastomer was used to allow the ‘phantom’ fingers to flex and curve around a mobile phone for testing, regardless of its shape or size. Engineers and model-makers worked together to devise a specialist moulding technique which cancelled out the issues raised by the materials and system design itself. After producing numerous prototypes, the model-making team found that a moulding system which encompassed half pressure casting and half vacuum-casting was most efficient and effective.

O’Horo continues, “Working with such thick materials can be a real challenge when moulding , but by having all the rapid prototyping techniques available to us we were able to rapidly develop a custom injection process. Having an in-house SLA machine (Stereolithography) to produce durable master 3-D parts from which to make the moulds also reduced lead times. By perfecting the process, we have also cancelled out the possibility of wasted imperfect models, allowing the client to supply demand quickly and effectively.”

IDC Models has produced over 20 phantom hand models for Indexsar in a variety of sizes to meet the demands of the mobile phone design. Each model has been produced using the customised technique.

7 July 2010

New Biker Helmet Design Speeds Ahead in Safety

With over 80% of fatal motorcycle accidents due to head trauma, rotational head injury is currently seen as the greatest cause of brain damage or death for motorcyclists involved in road accidents.

The new helmet, aptly named SuperSkin®, tackles this directly using a special new technology that mimics nature’s own simple design – skull and skin. Vastly superior in design compared to standard helmets, stringent tests show that the SuperSkin® product design reduces rotational impact by an unprecedented 50% and the subsequent possibility of brain damage by 67.5%*.

Managing director of IDC, Stephen Knowles, explains, “Traditionally, motorcycle helmets have been rigid in design. We needed to introduce a dynamic element of movement to dramatically reduce the rotational impact which often causes life-threatening injuries. On impact, the outer membrane is able to stretch and slide over the main helmet shell to prevent these dangerous rotational forces being transmitted to the head and brain.

Without breaking from the standard helmet shell, we developed a product design that was optimised for manufacture and rigorous international testing*. The end result has provided a first for the motorcycle industry and a great leap forward in safety.”

The product development process brought together IDC’s engineers, model makers and designers to develop a skin-like membrane that would slide on the surface of the helmet without breaking on impact. CAD software provided a quick means to transforming the concept into a series of tangible designs. But central to the intensive research and development process was rapid prototyping. Precision CNC machining paved the way for multiple impact absorbing liners for the helmet to be scuplted from a polystyrene block with optimum absorbence performance, allowing the team to test each design change along the way. The membrane was also tested in the same way.

The revolutionary product design required careful selection of materials. A strong synthetic sits on top of the gel-like lubricant to form a protective layer across the surface of the helmet. State-of -the-art vacuum casting was used to create prototypes and the materials tested for resistance and strength. The chosen synthetic stretched up to eight times its original length.

IDC is currently working with Dr. Phillips to develop other applications of the technology and an equestrian version is currently under test.

Brought to market by major helmet manufacturer Lazer Helmets SA the Superskin® will hit the shelves this summer. It is available in Lazer’s stylish full-face Solano (£200) or open-face Rider (£150) range.

15 February 2010

IDC Models Injects New Moulding Service

The new injection moulding service will provide a much-needed midway option for many and complements IDC Models' current stereolithography rapid prototyping and vacuum casting capabilities.

Traditionally, injection moulding has been associated with high volume manufacture due to the time and costs involved in making the moulds and setting up for a job. In addition to its rapid tooling techniques, IDC Models is keen to offer the benefits of its small, flexible injection moulding machine as standard to all companies regardless of quantity.

Vince O’Horo, director of IDC Models, explains the move, “This is a remarkably cost-effective option for customers who need higher volumes than vacuum casting or need to use an exact grade of plastic. For low or medium volume manufacture in particular (200 to 5000 parts), the costs of a production injection moulding tool is uneconomic and the delays are often several months. By using in-house rapid tooling methods it becomes a possibility for everyone, whether a company needs just one model or thousands. We can speed up the process, reduce cost and choose a tailored production method best suited to the customer’s needs.”

The in-house injection moulding capability has additional benefits too. Where SLA prototypes and vacuum castings have limitations in the materials that can be used, injection moulding fills the gap allowing products in the medical or food sectors, for example, to be tested realistically before manufacturing the final product. Numerous materials can be incorporated into the injection moulding process following rapid prototyping, including metal and resin.

Rapid prototyping and model making expert Vince O’Horo continued, “This is also particularly helpful for companies creating specialist products who need to just test part of a product but don’t require multiple prototypes. The injection moulding tool can make that happen swiftly and without breaking the bank.”

9 November 2009

IDC Designs Awards for UK Tour Series

Tasked by the organisers of The Tour of Britain and The Tour Series, SweetSpot Group Ltd., IDC's model making specialists and product designers have collaborated to develop a unique trophy design. IDC is very familiar with the detailed product development process involved in creating an award. The company recently worked with New Pro Foundries on the high profile film and television award, BAFTA.

Vincent O'Horo, Director of IDC Models, explains, “The Tour Series is a fantastic set of ten events which sees a return to competitive cycling in Britain's towns and cities. As a new Series, we needed to produce an award that would be instantly recognizable and in line with the brand itself so that it would become iconic in the cycling world.”

Continue reading 18 June 2009

3D Model for British Gas at Grand Designs Live

The British Gas stand at Grand Designs Live 2009 has a more interactive feel this year thanks to a demonstration unit crafted by IDC Models. The model showcases energy saving techniques tried and tested by the public in an eco-social experiment conducted by British Gas in 2008 called 'Green Streets'.

"Grand Designs Live and British Gas were keen to show the best of the energy saving devices put to the test throughout 2008 by some of the homes in eight chosen UK streets. Grand Designs wanted visitors at the show to get involved and see clearly in a fun and interactive way how these techniques really worked," explained director of IDC Models, Vince O'Horo. "Building a model that would create a life-like quality was essential. We needed to draw people in and bring it closer to reality for anyone visiting the show."

IDC Models was asked by Rockwool Insulation to design and produce the temporary demonstration unit.

Continue reading 18 June 2009

IDC Models Supports Production of Ground-Breaking Shower Head

Working for Challis Water Controls, IDC Models has been involved in a ground-breaking project to develop a new shower head which saves precious water resources and heating costs. The new Challis shower head is so effective that it can save up to 30% of hot water while still providing the same flow strength of a full flowing conventional shower head.

Continue reading 24 September 2008

IDC Models Creates Low Volume Spectrometer

IDC Models has supported Specac in the design of a special portable spectrometer called Prospect XL 3000 that uses the company's innovative new infra-red spectroscopy technology for use in process plants. With low volume production in mind, IDC was tasked with the rapid development of a new product that harnessed all the advantages of Specac's new technology, without the weighty costs associated with injection moulding tooling.

With a hi-tech workshop on site complete with laboratory facilities, IDC Models was able to swiftly produce a rapid prototype of the portable spectrometer in-house. As a result, injection moulding tooling was redundant, leaving out the worry of long delays and high costs.

Continue reading 24 September 2008

 

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