Portfolio / Models

With the blend of traditional hand-craft skills and modern CNC machining technology, the team at IDC models were able to produce accurate full size models of a rapid transport payment terminal. The spray-painted and accurately finished models were used in ergonomic user interaction tests to allow Almex to fully evaluate their design before progressing to full production; this can be one of the most important steps in any product development process.
At IDC Models we pride ourselves in producing both aesthetic models and working prototypes; this was the case for Avery when they passed the development of their new scales over to IDC Models. Starting with accurate block models, the project progressed up to fully functional rapid prototypes made using vacuum casting techniques for user testing.
Working alongside IDC’s design and development team, IDC Models were key in producing both assessment block models, and aesthetic final models for a new design of hedge trimmer. Using a wide range of specialties including, CNC machining, vacuum casting, and painting, IDC Models delivered a series of photo perfect models for assessment.
As part of a new product development project for B&Q, our model makers used CNC machining and hand crafting skills to construct white block models for both ergonomic and 3D geometry assessments. White block models are a fast and cost effective way to evaluate a product before moving on to more detailed stages of the development.
As part of a research and development project for B&Q, our model makers used CNC machining and hand crafting skills to construct a full size lawn mower block model. These were used to obtain marketing approval prior to ordering injection moulding tools. Full size block models are a fast and cost effective way to evaluate a product before moving on to more detailed stages of the development.
Working alongside a well-established casting company, IDC Models utilised their finishing expertise to provide post machining, polishing, and assembly for the world famous award trophies. A long running relationship between IDC Models’ Pattern Makers and the casting company has created a trusting link with IDC models for repeat business and widespread recognition.
IDC Models initially used CNC precision machining and hand carving techniques to create a series of sculpted foam models. Boots were keen to work with IDC Models for their proven track record in manufacturing evaluation foam models to tight deadlines. Following approval of the form, the IDC Models team worked with IDC Engineers to make functional prototypes of the innovative pumping valve.
IDC Models have produced the cycle helmet liners that will be used by the British Cycling Team at the London 2012 Olympics. These were made on site using IDC Models high-tech prototyping facilities. The cycle helmets were first and foremost designed for optimum safety, but also needed to be lightweight and streamlined for speed. IDC was able to apply its wide knowledge in this field, having previously developed the revolutionary anti-rotation Phillips motorcycle helmets. IDC developed the core safety component of the helmets, the liners. Each liner fits in the space between the aerodynamic outer shell of the helmet and the cyclist’s skull, so it was essential that it provided maximum protection in case of an accident.

The helmet liners were manufactured from Styrofoam, which was selected for its light weight and excellent impact absorption. The liners were machined using IDC’s Rye CNC milling machine. Forty helmet liners were produced, which then went on to have the final casing with British team graphics applied.

This is the second time IDC Models has been selected to produce the cycle helmets for the British team. At the Beijing Olympics the team came home with gold medals so hopefully we will have the same success at the London Olympics.

Image provided by: © Mark Eaton | Dreamstime.com
As a popular choice for clients looking to create exhibition pieces, IDC Models were asked to produce a 100% lifelike model of an integrated sink and dishwasher for use in the home. Blending both hand crafted pieces with CNC machined parts and sourced OEM components, our team was able to deliver a showcase model which would stand up to even the most detailed scrutiny.
As part of the full service integrated team at IDC, our model makers worked with IDC design engineers to produce full size, fully finshed aesthetic models of a new PCB printer designed by IDC for DEK. These were used to showcase the fresh designs at exhibitions and trade shows to great success. IDC Models would later produce fully working prototypes of the final designs.
With a keen eye for detail and experience with large scale models, our team was able to develop a long term relationship with DeLaRue by providing a series of aesthetic block models for their evaluation. With CNC capabilities and full paint booth spray shop, the model makers were able to recreate every element of the designers’ vision with flawless results. Stereolithgraphy was used to manufacture detailed features and parts.
As a repeat client of IDC Models, Hamworthy required a full size 2m x 2m exhibition model of a new prototype boiler system for them to showcase. The team’s combined skills in model making and finishing were coupled with the use of CNC precision machining to provide an accurate photo-perfect, large-scale model in a short time scale.
Index SAR approached IDC Models to aid them in creating accurate 3D prototypes of human hands to be used at the Nokia mobile phone R&D department for ergonomic and radiation tests. IDC Models provided 3D printing services using our SLA machine to create the patterns to be used for low volume vacuum casting. The prototypes parts were then vacuum cast in a variety of plastic and rubber materials to be used in testing.
Designed to reinvigorate the previously traditional Mega-Yacht scene, IDC Models recreated Kelvin Hughes’ vision for a new era of bridge installations. With only four weeks to make a fully working model, our model makers worked round the clock using CNC machining and rapid prototyping to create the bridge replica. The finishing touches included paint, graphics, and OEM components to bring it to life.
LEGOLAND commissioned IDC models to design and manufacture a Ninja themed \'Lego Mini Land\' to be sited in outdoor shopping centres across Europe. The brief was to design and manufacture various mechanisms to power the LEGO animations. It was crucial that these mechanisms were robust, simplistic, weather proof, corrosion free, and thief proof and able to run for 12 months straight with virtually no maintenance needed.

IDC models came up with the mechanism designs in -house which they then machined, assembled, tested and delivered. The techniques used included manual and CNC machining. The process involved consistent testing of parts to ensure they met the criteria set by LEGOLAND. The designs were developed and improved on in order to overcome any obstacles found in the testing stages.

IDC models were chosen by LEGOLAND for this project because of the experience and ability of the team. The models have been taken over to Germany where they have been sited in outdoor shopping centres and proved to be a big hit with the public.
In supporting Linde\'s vision to develop a new range of reach trucks for taller warehouses, IDC Models produced a life-size block model of a reach truck using a variety of different model techniques.

Supplied with a steel chassis by Linde, the team built a full-size model based on Linde\'s CAD design specifications. Being a new style of reach truck with the potential to reach over 12 metres, Linde was keen to check usability on a full scale model. IDC\'s design engineers also developed a control console for the reach truck and this was incorporated into the model to be tested by users.

IDC Models\' large format CNC machine was used to create the main parts of the truck from \'ureol\' precision modelling blocks. Smaller components, such as the windscreen, joysticks and knobs, were developed by first 3D printing the components by SLA to form masters and then producing vacuum casts based on these.

The components were pieced together with an exceptionally high standard of workmanship and then sprayed and finished on-site at IDC Models. To make the model as realistic as possible, Linde supplied additional finishing touches such as rubber seals and other smaller components.

The model was instrumental in helping Linde test and refine this futuristic reach truck and enabled them to develop a pioneering new range of materials handling trucks.
POSITIONEERING Limited commissioned IDC Models to improve the aesthetics of a case part used to hold their high-tech precise satellite-positioning device. The device will be used in offshore applications throughout the global oil and gas industry to accurately locate vessels engaged in exploration for hydrocarbons as well as the construction of oilfield infrastructure including the placement of items on the sea bed. The device constantly adapts to recognise signals from multiple satellite constellations including GPS, the Russian equivalent, GLONASS as well as the future European and Chinese equivalents, Galileo and Compass respectively. Making simultaneous use of a minimum of 4 satellites through to an expected maximum of over 50, the system, when coupled with Positioneering’s global enhancement-service broadcasts, provides highly precise positioning and navigation to within 5cm accuracy; normal GPS devices are only capable of providing a reading within 20 metres of an object.

To contribute to the completion of this already stylish and high-quality product, IDC Models was able to develop a suitably high-quality finish for the casing. IDC Models initial work included anodising the main housing coupled with the application of a tough paint finish of the detail elements of the product. The resulting units were used at the product launch during the Oceanology International exhibition last month in London. Ewan Brown, Global Production and Resources Manager at Positioneering expressed his gratitude stating, “The show was a great success for us and having the units there played a big part in that.”
With expertise in both aesthetic and mechanical models, our team worked with the creators of Sindy to produce a fully working mechanical bicycle model. Functional plastic parts were created using our SLA rapid prototyping service; coupled with vacuum casting, with minimal finishing needed these parts ready for assembly in a matter of hours and could be approved for production of injection moulding tools.
IDC Models turned a dream into reality for Red Bull Racing by taking the surface data provided by Sony Playstation/Polphony and turning it into a solid and full-scale model of the Red Bull car. The technologies utilised in order to create the life-size car model included: CNC Machining, Stereolithgraphy, Selective Laser Sintering, Vacuum Forming, Drape Moulding and GPR Moulding.

IDC Models was challenged with the task to complete the life-size model of the dream car in just four weeks. Using data supplied by Polyphony in Japan, the model has been assembled in sections to its full size of 4.75 meters long by 2.2 meters 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 flexibilities. IDC Models is one of only a few rapid prototyping bureaus in the UK with large-scale CNC facilities.
As a provider of cutting edge insulations to British Gas, Rockwool have repeatedly used IDC Models’ services to supply them with exhibition stand models and cut-away educational demonstration stands. Working closely with the client to ensure accurate representation, IDC Models provided a fast turnaround and remarkable attention to detail on these full size exhibitions stands to great success at the shows.
IDC Models started by making a series of block models for evaluation using CNC machining, and progressed to batch production of 30 working rapid prototypes. A pattern was first created from a 3D printed SLA rapid prototype from which 30 plastic prototypes could be moulded using vacuum casting. These were finished, assembled, and tested prior to delivery. The samples were used for assessment prior to injection moulding.
With a reputation for high quality batch production services, IDC Models were asked to both design and create a series of trophies for both the Tour Series, and Tour of Britain cycling competitions. Held every summer in the UK, IDC Models are now a repeat provider to Sweetspot after a successful debut in 2009. IDC Models worked alongside the design team at IDC to provide innovative designs, sand-cast pattern making, as well as full low volume production of the trophies.
Swiss Air approached IDC Models with a new design for their first class cabins. Drawing on their experience in mechanical assemblies and large-scale prototypes the team succeeded in recreating a full size cabin mock-up including fully working seats and mechanisms. These were both robust and functional for aesthetic review and user testing.
With a new design for the- classic Thermos flask, IDC designers and engineers worked with IDC Models to produce a short run of production quality parts using our rapid prototyping and vacuum casting capabilities. With the ability to accurately reproduce components from 3D printed patterns or actual parts, vacuum casting is a cost effective and high quality solution for low volume production. The final injection moulded flasks have been sold in their millions.
IDC Models, is helping to keep vintage British motorbikes on the road with projects working for Tri-Cor England, which specialises in spare parts for Triumph motorcycles that are no longer produced.

IDC Models has worked with Tri-Cor for a number of years; producing custom made parts for Triumph motorcycles using its high-tech model making facilities. Its latest project is to produce a cover that hides the oil tank and toolbox just under the dual seat on the Triumph Twin & Triple motorcycles.

IDC Models identified the need to produce new patterns for the covers. Once the patterns were made, IDC used ABS sheet to vacuum form the covers. Each cover was then trimmed and finished using CNC machining.

Andy Gregory from Tri-Cor, commented, \'These covers went out of production many years ago and are now highly sought after. We can rely on IDC Models to produce these and other spare parts to an exceptionally high standard. They are able to make patterns for each part and produce them to order.\'

Peter Penderdast, Head of Production at IDC Models, commented, \'We are delighted to continue our work producing parts for Tri-Cor - and at the same time support the heritage of British motorcycles.\'
IDC Models used its high resolution SLA Viper machine to manufacture precision 3D models of the smallest hearing organs known to science.

The University of Bristol required a model of the katydid insect’s ears for a research project focussed on how the insects actually hear, as their ears are up to 100 times smaller than the sound waves they are listening to.

IDC Models, as one of only a few companies who offer micro 3D printing, was able to provide a life-size replica of the insect’s ears and successfully recreated the structure which was almost impossible to investigate using other techniques.

The micro printing capabilities of IDC Models has helped to support research projects studying the physics behind hearing, which are aiming to advance the technology of human hearing aids in the future.
With the ability to produce twin shot parts using our vacuum casting machines, IDC Models created a series of over moulded prototype tooth brushes. With a high density plastic base and durable rubberised over moulded grips, these models gave the impression and feel of production parts at a fraction of the time and cost.