Pascoe Tender Model for Ken Freivokh Design

March 15, 2016

This compact 1:30 Pascoe Tender model demonstrates that small, economic models do not trade off detail or quality for cost. The main mass of the model was 3D printed to give us our forms and tolerances, and brought to a pristine finish by hand. The scale allowed us to incorporate fine touches such as the perforated canopy, hardwood veneer decking - all mounted on a stainless steel base with matt black graphics. The model was made a part of a collaborative project between Amalgam Modelmaking and Ken Freivokh Design. The marine and naval models we create for our clients typically reach sizes almost up to a metre, being superyachts and large sailing craft. This model, being a smaller class of craft but made at a larger scale, allows intricate detail and design features to be accurately represented and a certain level of engaging realism to be achieved. Tender models of…

March 15, 2016

We make marine models for a broad range of scenarios; chunky industrial engineering models, conceptual 'Speedforms' for designers, and high-finish display pieces for marketing suites and trade shows. The Antares yacht model was a private commission by the yacht's owner, and as such the construction decisions and material finishes were made with the model in mind as a bespoke luxury object, equal parts craftsmanship and engineering precision. We used 3D printing processes and CNC machining to create the bold forms of the design and give us our basic substructure. These computer-aided methods served as a foundation for hand-made details and finishes, and we covered the model in masts, booms, cleats and struts, all being hand-shaped metal components. We used a fine grained hardwood veneer to recreate the decking, gently laser engraved with the intricate join lines and hatches; the keel is the only point of attachment to the stainless…

September 24, 2015

This cutaway display model is largely 3D printed; only the outer sleeve was hand-fabricated, with the impellers and other internal structures created in-house on our Objet machine. The combination of a high level of accuracy and speed allowed us to focus on creating smooth, highly graphic surface finishes for the colour-coded components, and ensured that the hand-finished parts fitted snugly together in their assembly. This cutaway display model is intended to show the internal mechanisms and principles of the SPX Flow Technology CEP unit. While it is a near exact recreation of a production unit, the pump is presented here almost as a technical illustration in three dimensions. This allows important and innovative features of the design to be effectively highlighted and explained to the audience. We have made a range of models of this nature which have proven to be particularly successful in exhibitions, trade shows and industrial events,…

September 24, 2015

This incredibly intricate industrial display model is a great example of the impact new digital technologies can have on modelmaking. The bulk of the work took place purely in the digital realm, taking nearly five weeks to process client-supplied CAD into a kit of 3D printed parts that could be snapped together in a morning. The original digital model of the Continuous Processing System was provided to us at 1:1 scale, was meticulously edited from an engineer's technical specification to a file that was ready for 3D printing at 1:20 scale. This involved resizing the pipes so that none were less than 1.2mm diameter (based on the resolution of the 3D print), and digitally joining together over 6000 separate components into 8 single pieces. After this extensive conversion period, the forms were 3D printed in colour. Unlike many display models, the 3D printed parts required no finishing of any kind,…

September 24, 2015

This section model was created almost exclusively with 3D printing processes, each component being meticulously hand-finished to fit snugly back together. Having received the client's design, our technicians extensively processed the technical CAD into 3D print ready files. Each face, curve, ridge and internal radius was carefully sanded and top-coated to achieve a high-quality graphic finish. The colours are intended to highlight the different functional components of the unit, matched to the client’s specification. To complete the high-end display model, the whole assembly is mounted on a crisp gloss black presentation baseboard. Display models presented in this manner are incredibly useful sales and promotion tools. While this model is a detailed bolt-for-bolt replica of a production unit, it is presented as a highly graphic, illustrative section model – almost a technical drawing in three dimensions. The advantage this manner of presentation has over screen displays or static images, particularly in…

September 8, 2015

The process of creating the 'Scrumpty' character combined character design, an element of branding and short-run manufacturing techniques. We designed Scrumpty from an initial written brief, managing the whole process from concept sketches, hand sculpts, digital reproduction and a final short production run. An overview of the design process can be found here. We created Scrumpty for Marketing Gloucester, as a friendly figure combining the city's Rugby heritage with its famous 'Humpty Dumpty' fairy tale. The design of the character was intended as a blank canvas, as part of a competition open to the public to submit their own paint schemes and ideas, with the winning entries being stationed around Gloucester city centre in a 'Scrumpty Trail'. Amalgam's own Jenny Sealy and Elaine Carr were among the winning entries, with a 'Hard Boiled' Scrumpty and realistic apple-skin finish respectively. We used manufacturing methods that would ensure a reasonable amount of durability,…

August 4, 2015

We have made a range of video props for Stripeland over the last few years - but this one stands out for us. The brief: "To refit a supplied pram in the style of an American hip-hop vehicle, complete with chrome spinning hubcaps, oversized tyres, ‘bounce’ mechanism and gold flames." Amalgam's video prop makers do love a challenge and design agency Stripeland's video directors and producers know where to turn for innovation and unusual props. So we like to think we were their first thought when asked to make this promotional video for the Red Cross's on-line campaign promoting "RappedUp", a first-aid app for babies and children. We took a small carry cot and a large pram chassis, which were not designed to go together so emphasised the scale discrepancy, and created a hybrid vehicle. The reference material the client supplied was the ubiquitous low-rider car beloved of the hip-hop…

June 17, 2015

These simple and engaging interactive sales models, made for Map Environmental and their stand at the CIH Housing 2015 event, show three different scenarios for PV modules, installed in a modern home, an industrial warehouse and a school. The models also include simple lighting elements, which are activated by switches integrated into the building detail, such as doors and vents. We regularly make models along these lines, and they are proven to be effective marketing tools, particularly with sustainable consumer technologies. Along with the solar panels demonstrated here, we have made public engagement models demonstrating air and ground source heat pumps, industrial LED lighting, home insulation and hydrogeneration turbines. These models tend to be relatively economic, since the level of detail is usually simplified to show a product in a generic context that potential consumers can relate to or understand. In some cases, such as the Biomass Energy Model, they…

June 1, 2015

The team from Zodiac were also very insistent that these mock ups had to be of the very highest quality - and durable enough to survive the world's biggest event of its kind without showing signs of wear or damage by the end. They had, had a few bad experiences in the past and told horror stories of less than perfect seat mock ups being pulled off of the stand at the last moment - something they were obviously keen to avoid. A joint and combined effort was the only option. Zodiac and Amalgam worked closely throughout to coordinate their CAD resources, in-house and outsourced CNC machining, 3D printing, specialist upholsters and several couriers with military precision.

March 20, 2015

Medical Product development by Amalgam to support P3 Medical’s launch of Tube Anchor Intravenous therapy is commonplace during hospital stays, yet the way a cannula is secured means it can still tug and move, causing increased risk of infection and the need to replace the cannula frequently. Having spotted this as a commonly painful issue for patients, Professor of Endocrinology and Honorary Consultant Physician at University of Bristol, Andy Levy, came up with the idea for Tube Anchor. He recognised that a simple, disposable component could overcome this and started working on sketches and handmade prototypes in his home workshop. Very quickly he realised that fine control over materials and the geometry of the device were critical to developing the idea for wide-scale use in healthcare. Professor Levy went on to review his plans with healthcare innovation support specialists CareTechnica, who worked with him to analyse the commercial opportunity, and…

Pascoe Tender Model for Ken Freivokh Design

Pascoe Tender Model for Ken Freivokh Design

Antares Yacht Model – Private Commission

SPX Flow Technology CEP Cutaway display Model

SPX Flow Technology Continuous Processing Industrial Display Model

SPX Flow Technology FT Section Model

‘Scrumpty’ Branded Character Design

Hip Hop pram Video prop for Stripeland

Solar Power Interactive Sales Models

Full size mock ups of aircraft seats

Medical product design development