Portfolio / Prototyping

Working alongside IDC’s product designers and engineers IDC Model’s sculpted the initial foam models, which were created to assess the form. In a later stage, rapid prototypes of the final designs were made using CNC machining, Stereolithgraphy (SLA) as well as vacuum casting Processes.
IDC was approached to design a safer cell for HM Prison Services. After the project was designed, it was taken to the prototype development and tooling stage where multiple models were made allowing the IDC team to assemble a mock-up model and physically try each component making sure that it was ergonomically sound. Using the models as patterns, moulds were made in Glass Reinforced Plastic (GRP) for the spiral ladder and end wall support. The moulding tools for the thermoformed parts (bunk beds) were made in aluminium and epoxy tooling board.
After careful research on ergonomic design, IDC Models created prototypes of the Howmedica Knee Replacement Tool in order to evaluate the mechanical design used in real surgery. CNC Machining was used to create stainless steel prototypes with speed, accuracy and made sure of its durability during testing.
IDC Models was asked to create a prototype of the Philips Superskin Helmet. Precision CNC machining paved the way for multiple impact absorbing liners for the helmet to be sculpted from a polystyrene block with optimum absorbance performance, allowing the team to test each design change along the way. The membrane was also tested in the same way. State-of-the-art vacuum casting was used to create prototypes and each material was tested for resistance and strength. Cutting edge paints and spray-painting techniques were used to create the high quality aesthetic model needed.
The Quaffer is a double bubble shot glass with a built in chaser that guarantees the customer the best shot they have ever had. The design of the product allows 1oz of liquor and 2.25oz of chaser to be stored separately until the drink is consumed.

IDC manufactured the prototype using its in-house Stereolithography (SLA) machine, a 3D printer that constructs models by selectively hardening liquid resin. The process involves slicing a CAD model into cross-sections which are traced by high-power laser onto the surface of the resin. The resin cures and hardens where the laser hits, allowing objects to be built up layer by layer. The result is a plastic part with a superb surface finish ready for market.

The Quaffer is available to purchase here.
IDC Models was commissioned to develop a prototype for a \'Robotic Pill\' designed to deliver medication to a targeted area of the intestines. The pill is swallowed by a patient and travels naturally through the patient\'s body to the small intestine. Its movements through the body can be tracked by the medical team. When it reaches the target location, the operator sends a remote signal to the robotic pill instructing it to send out its legs to hold it in position. The medical team can then instruct it to inject medication directly into the target site.

To make the prototype IDC Models used their Viper Stereolithography (SLA) machine, a 3D printer that constructs models by selectively hardening liquid resin. The total size of the pill was only 30mm by 11mm, so they needed the most precise equipment to produce these parts.

These prototypes are the smallest parts every to be produced on IDC Model\'s SLA machine and are being used to secure further investment into product development for Imperial College
IDC Models used their Viper Stereolithography (SLA) machine to construct this microchip, used for maintaining biological sample integrity during x-ray diffraction.

With dimensions of only 20 x 12 x 1.5mm, this is one of the most intricate parts ever produced on our machine. By producing an SLA prototype, Diamond Light Source are able to understand the chip architecture, where the channels are best positioned and the exact sizing of the chip reservoirs required.