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additive manufacturing

Development of the Holovis game controller for immersive 3D experience

Holovis D3D header

Published in this month’s Develop 3D, you can take a look behind the scenes at the development work we did for Holovis to design and manufacture the Crimson Wing game controller. Holovis came to Amalgam with a basic outline shape developed as a 3D concept. Their first priority was to develop the ergonomics, starting with the handle of the controller. To test each handle design, we made controller handles out of modelling foam, using our 3-axis CNC machine.  Once we determined the desired shape and best size, we adjusted our CAD model and applied finer exterior design details to it. The concept version was then shelled out, for us to apply all the required internal features and electronic support bosses.  The next stage was to develop our CAD file into a final design, which took four weeks of computer-aided design work.  Once the CAD files were complete, we 3D printed…

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Process flow models – to realise a 3D proof of concept

Some clients come to us for a model, when making engineering changes, or re-designing a process flow. These businesses may be working in manufacturing, or energy sectors, where the changes need to be shared with stakeholders around the company, and across the industry. So, today we take a look at the top reasons why a 3D model helps, when explaining a complex or technical process flow. Top reasons for creating a process flow model 1. When a concept is highly technical, a model enables you to simplify it - and use dynamic lighting or coloured parts to mark specific aspects. The SPX Flow Continuous Processing Industrial Display model (shown above) is a great example of how we apply our CAD skills to develop a design ready for 3D-printing a huge number of component parts. Once the parts were finished, they simply clicked together to create the eye-catching industrial display, showing the…

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Additive Manufacturing used in Bruce Munro Artworks

Bruce Munro's ICOS

Additive Manufacturing is a media buzzword these days, newspapers and the media generally grab every opportunity to broadcast how 3D printing (The popular term for Additive Manufacturing) is revolutionising everything from fashion to domestic appliance servicing.  Here at Amalgam we have been using a range of Additive Manufacturing processes for many years to help our clients realise their designs and have been both amused and frustrated by the sheer volume of (Largely inaccurate) coverage this "New" technology has been getting of late. One area where we can report that Additive Manufacturing has been used to great effect is in the artwork of Bruce Munro, best known for immersive large-scale light-based installations in Britain, the USA and beyond. Bruce and Amalgam have worked together on several projects in the past including Mettabhavana, conceptual piece conceived by Munro in the late 1990s which we built in model form using Stereolithography for the…

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Additive layer manufacturing: From ‘art’ to ‘part’

EEF, the manufacturers’ organisation, in conjunction with Materials and Design Exchange (MaDE), Materials KTN and Exeter University Centre for Additive Layer Manufacturing (CALM) recently held an event at Exeter University to inform businesses in the South West  about the range of services and technologies available in the region. The day was organised by Phil Brownsord of EEF and John Bound of MaDE, the Materials and Design Exchange, a part of the Knowledge Transfer Network and featured speakers including Nick Grace from the RCA, Dr. Sara Flint of CALM and Amalgam’s own Mike Harvey. Apart from the various presentations which covered various aspects of Additive Layer Manufacturing and Product Development the day also included a tour of CALM’s impressive facilities with Richard Davies and James Bradbury providing demonstrations of the various processes on site. Additive layer manufacturing Often referred to simply as "Additive Manufacturing" or "AM" is a branch of 3D printing -…

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