Energy Home Display Model

May 3, 2012

Client: The Centre for Sustainable Energy The Energy Home was a model designed to show the public simple and practical ways to make a home more energy efficient; a sense of fun was encouraged to make the model more engaging to the public. The model demonstrates practical ways to create an energy efficient home, with details such as draft excluder snakes, a solar panel array, roof and pipe insulation, and energy-efficient appliances. To make the model easier to transport, the house neatly slots and locks together into a manageable, transportable unit.

Respirator HUD

May 2, 2012

Client: Avon Protection The Heads Up Display (H.U.D.) is a 3 part prototype which utilises two materials with different hardnesses. The hard part forms a water tight capsule to house a feedback indicator for a respitory system. This is encased in a flexible ring which attaches the device to the user. High tolerance finishing of the 3D printed master model ensured that the parts mated when cast.

Speedwrap cling film dispenser

May 2, 2012

Client: Wrapex The working prototype for this cleverly-designed clingfilm dispenser incorporates over twenty individually cast and fitted mechanical components, as well as a custom-milled cutting mechanism honed to within fractions of a millimeter.

HM50i Mask

May 2, 2012

Client: Avon Protection The HM50i permits the rapid attachment of an Avon respirator to a Tactical or Law Enforcement helmet without having to remove it completely. By replacing the traditional harness, wearers can rapidly gain respiratory protection against riot control agents or harmful substances, without a temporary loss of physical protection. This working prototype was cast as a single piece, and incorporates tolerance snap fittings to attach respirators and filters. It also features cantilevered spring details, adding further functionality.

SnowBuster – Low volume plastics production

May 2, 2012

Client: Snow Business Low volume plastics production is something that our vacuum casting systems excel at. A good example of this is the Snow Business SnowBuster, which is designed to provide weather effects for the film and TV industry. Previous versions of the device were so noisy that they had to be switched off before recording started, being needed again after only a short burst of filming because the falling "Snow" was clearing. Snow Business approached Amalgam with the idea of producing a quieter version but, due to the highly specialised nature of the device it was clear from the outset that low volume production was going to be the only practical method of producing the plastic parts. The entire housing shown here was designed, developed and produced in-house by Amalgam. The SnowBuster makes a cameo appearance in this Boots 2011 Christmas TV Ad.

Thinking Cap Machine for The Science Museum

May 1, 2012

It must be every exhibition designer's dream to be asked to make an exhibit for The Science Museum. This giant 'Thinking Cap' exhibition model was developed and built at Amalgam based on Nick Park's idea for the show stopping finale to the 'Wallace and Gromit Present a World of Cracking Ideas' exhibition. The size 97 stomping boots drive the 'cap' up and down while it 'processes' ideas, shooting wearable paper caps from its mouth for visitors to take home. Amalgam's multi-talented Exhibition team worked round the clock to build 'The Workshop Zone' of the show, which included a pair of three meter tall vertical scrolling graphic displays, a wind-up desk workbench, and the 'Ideas Safe' vault room designed to 'protect' ideas. Having designed and built the exhibits in our Bristol workshops the team relocated to The Science Museum to finally install and commission the pieces on-site. The exhibition opened at The…

Swimtag training aid prototype

April 30, 2012

The Swimtag training aid was developed in 2008 by Bath-based 222 Sport. The company was founded by a group of design students intent on developing a product to make swimming more 'engaging, interactive and fun'. Gareth Jones, formerly of The Product Works, mentored the students to develop the initial designs. The Swimtag was developed as a prototype in collaboration with Amalgam's specialists, who developed the concept for prototyping and manufacture, maximizing the use of ready-made components and minimizing assembly processes. In addition to the elastomeric waterproof writsbands, we also produced prototypes of the docking station, all by vacuum casting. The Swimtag, a ‘training aid and monitoring system that tracks your progress in the pool,’ was brought to market in Summer 2011. The vacuum casting facilities at Amalgam, and the experience and knowledge of the staff, have enabled us to have a real hand in some of the prototyping projects that…

S.E.N. School

April 30, 2012

Client: Hunters Architects This is a 1:300 scale model constructed from wood and acrylic with a removable roof to show the internal layout. It was commissioned as a Public Consultation model, and the building has subsequently been built as a school for Special Educational Needs.

Eircom Russian Dolls

April 27, 2012

Client: Aardman Animations Aardman Animations Director Danny Cappozzi designed the monochrome set and colourful characters for this animated commercial for Irish telecoms company Eircom. The eye catching puppets are a contemporary take on a traditional Russian doll. Specialist artists from Amalgam spray painted the bright block colours then airbrushed and hand painted the finer details of the puppets.

Caspian Superyacht Model for Claydon Reeves

April 27, 2012

This superyacht model follows up on Claydon Reeves' successful launch of the Remora 80m yacht in 2010. The 850mm 'Caspian' model was the centerpiece for the 2011 Monaco Yacht Show, and was accompanied by two elegant Speedform models, which illustrate the basic forms and fluidity of the designs. We can can construct a superyacht model from technical drawings or from freehand concept sketches. Either way, our in-house CNC machine is able to carve out symmetrically perfect 3D hull and bow forms, to be finished by traditional hand skills and craftsmanship. Extra details such as furniture and masts serve to bring a superyacht model to life; it is often these small additions which are the most engaging, since they create a sense of scale and draw in the eye. More details on the Caspian can be found on the Claydon Reeves website.