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SPX Flow Technology Continuous Processing Industrial Display Model

  • September 24, 2015
SPX Flow Technology Continuous Processing Industrial Display Model

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 exceeded a 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, and…

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SPX Flow Technology FT Section Model

  • September 24, 2015
SPX Flow Technology FT Section Model

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…

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‘Scrumpty’ Branded Character Design

  • September 8, 2015
‘Scrumpty’ Branded Character Design

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,…

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Hip Hop pram Video prop for Stripeland

  • August 4, 2015
Hip Hop Pram Video Prop For Stripeland

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…

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Solar Power Interactive Sales Models

  • June 17, 2015
Solar Power Interactive Sales Models

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…

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Full size mock ups of aircraft seats

  • June 1, 2015
Full Size Mock Ups Of Aircraft Seats

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.

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Medical product design development

  • March 20, 2015
Medical Product Design Development

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…

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TERN 1/12th scale Yacht Model

  • February 23, 2015
TERN 1/12th Scale Yacht Model

Commissioned by a private client, this impressive yacht model was constructed at the same time the real TERN yacht underwent refurbishment to its original incarnation by Spanish restoration workshop, Ocean Refit. The projects, despite being drastically different scales, ran parallel to the point where design decisions and technical details were being exchanged in a collaborative process. Further input came from Chuck Demangeat, who assisted us in faithfully recreating the sails and rigging. These two projects - the refurbishment of a classic boat, and an accompanying scale model - are the products of pure passion. TERN itself has a prestigious history, being originally designed by nineteenth century designer William Fife, and constructed by John Hilditch in Carrickfergus, Northern Ireland. Nine of these Sea-Bird-Class boats were built, each named after a sea bird, and TERN was one of only three to survive the century. Between 1995 and 2000, the boat was modernised…

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1/400 Interactive Biomass Energy Architectural Model

  • December 4, 2014
1/400 Interactive Biomass Energy Architectural Model

This interactive architectural model of Sleaford Renewable Energy Plant, made for Crystalfish Communications and Eco2, is presented as a puzzle. Participants are encouraged to activate the separate stages of the biomass energy generation process by a row of buttons on the front panel. Only activating the stages in the correct order will result in energy being generated and fed out to the grid.   The interactive element of the model incorporates processors to digitally control the lighting and the whole electronic system was designed and wired together in-house. Some electronic issues we had to address included the securing and hiding of wires within the model - since some of the illuminated routes were suspended in the air on framed structures, we were limited in the objects we had to run wires through to effectively hide them.   To create a painted base that was artworked appropriately for an architectural model,…

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Mojo Maritime HF4 Dynamic Positioning Vessel

  • December 3, 2014
Mojo Maritime HF4 Dynamic Positioning Vessel

This model was built to demonstrate the Mojo Maritime HF4 as a flexible offshore platform, capable of being outfitted for a range of uses. The large A-frame was constructed to be articulate, and the model includes many fine details such as knuckle cranes, lifeboats, mooring points, propellers and other details to create a sense of scale. We embedded a steel plate beneath the deck level, giving the option of different magnetised components to be arranged on the surface, indicating different uses. The satisfyingly chunky hull was largely carved out on our CNC machine, before being assembled and hand-finished. The model was featured in Mojo Maritime's exhibit at SMM Hamburg 2014, the leading international maritime trade fair.

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