case studies

un cells

The story for Solve 3D started in early 2007 when Industrial Designer Matt Sinclair and Entrepreneur Morten Neilsen approached Chris to make the first three reference models for design evaluation.

An evolution later and in late 2008 Chris built the first 5 semi functional prototypes for the Basel Watch and Jewellery fair. The size shapes and proportion changed and the navigation key became a fingerprint reader. There were many first’s including the first Sapphire, mobile touch screen. Positioned on Ulysse Nardin’s main exhibition stand the semi functioning concepts were a showstopper. The excitement and interest in this unique product led to large orders from distributors.

Chris was asked by the owners of the SCI innovations to develop the full mechanical design to a ‘production ready state’, and to work with specialist suppliers from all over Europe to achieve the unique finishes on 11 models.

Working with UNCells chosen electronics partners, Chris led an 8 man mechanical design and prototyping team who worked closely with Chairman’s designer, Matt Sinclaire.

Chris and his team cultivated many successful working relationships with suppliers all over Europe but in particular, with Dutch micro generator company Kinetron whose world-class micro generators form the heart of the custom designed ‘Ulysse Nardin’ kinetic back up generation system.

Working in Parallel, 3 members of Chris’s team worked soley on developing the base station. Carrying the Ulysse Nardin name, the base station had to incorporate new technology with the quality & heritage of Ulysse Nardin

The team decided that a traditional marine chronometer box would complement Chairman and reflect the Ulysse Nardin DNA . During the 19th century Ulysse Nardin had supplied marine chronometers to the British Navy. However, In the 19th Century, these did not present a mobile phone as the lid was lifted neither did they contain a charging circuit, quality audio, Wi-Fi streaming, 32gb storage and data back up. Quite a different product in many ways.

A complex geometry of mechanical linkages was designed, engineered and developed by the team until the mechanical functionality was perfected to give the correct feel. Finish, fit and function were detailed with meticulous precision. Production tolerances and finish quality was dictated by the highest standards set by Ulysse Nardin.

gmc

In January 2008 the UK arm of the ‘Global Machinery Company’ or GMC asked Solve 3D to produce a model of their planned, next generation, hydrogen powered drill and charge generator.

The model was for a power tool exhibition in Cologne and had a series of challenges to overcome. The model had to faithfully represent all of the materials that were to be used in its final construction, even down to the hydrogen-gel power source. In reality the unit was to be a combination of anodised aluminium castings, stainless steel and gloss polycarbonate. In addition a number of elements were required to illuminate and stay in this condition for up to 8 hours on a rechargeable battery supply.

Working with lead designer John Hogarth, Solve 3D decided that this would have to be a project spread across its 3 sister companies. Solve 3D, Rapid 3D and 3D Definitive Coatings all had a part to play in this unusual project.

Accura ‘Blue Stone’ SLA parts were built on our SLA 5000 machine, post cured to withstand concentrated heat up to 250 degrees and then electro plated, first with copper, the surface finish applied then further plating with technical nickel, to represent pressure die cast aluminium.

The main charger frame was to have look and cold feel of brushed stainless steel and contain the deep embossed logo of the company. A high-density epoxy was machined and fabricated to form the frame. Then using a series of special chemical treatments 3DDC were able to apply 150 microns of copper followed by silver nickel to the epoxy model. This was hand brushed and then vinyl graphics applied. This finish was also applied to several of the drill components with the final plated finish of ‘Technical Black’ being applied to the drill chuck and the hydrogen-gel holder.

The plastic components were CNC machined from solid billets of cast white acrylic, hand polished and graphics applied. The hydrogen gel was represented as tinted, uncured silicone rubber which we encapsulated in an acrylic flask.

The final electronic lighting was a rudimentary circuit made up of low voltage LED’s linked to a rechargeable lithium mobile phone battery.

The total model build was 3 weeks and demonstrated the value of cutting edge rapid prototyping technology when in the hands of skilled traditional model makers.

british airways club world sky bed

In early 2005  the team at Solve 3D were approached by London based product design consultants Tangerine and asked to produce a full appearance mock-up of their re-designed Club World Sky Bed for British Airways.

The Initial model was a centre quad to be installed at British Airways cabin development centre. Working closely with project coordinator Matt Round of Tangerine Solve 3D commenced production with what seemed an impossible deadline.

Construction and detailing data changed on an almost daily basis during the whole period of construction. At this early stage, only the basic principle of how the construction was to be assembled and held together was understood. The reality of how all of the components of the model would lock together, hinge, slide, and be demountable was left to the engineering design skills of Solve 3D. A light weight construction was essential; however the structure had to be able to withstand fully grown adults treating it as they would a production assembly. It was testament to Tangerine’s design work that the form of the surrounding structure was inherently strong and self supporting; however with such a tight time scale it was left to Solve 3D to “make it happen”. The additions of Leather trim and meticulously executed final detailing preceded installation in the CDC, on time and on budget.

For the remainder of 2005 Solve 3D modified the mock-up and built a number of strong test rigs for ergonomic appraisal by tangerine and BA.
By the end of 2005, the design was finalised at which point Solve 3D produced a further mock-up of the ‘centre quad’ formation to assist with the familiarisation training of the cabin crews.

January 2006 and Solve 3D were once again asked to produce mock-up’s of  an entire  row, consisting of a quad, a left and right hand window pair and 10 free standing foot, stools for assembly in the CDC. These mock ups were of the up-to-date design and for the final press launch of British Airways ‘Club World’ seating. The models were correct in every detail, strong enough for normal use, in addition they demonstrated articulating monitors, trays and foot stool positioning.

By May 2006 Solve 3D had completed the work, on time, on Budget and to the total satisfaction of Tangerine and British Airways.

Only a small number of companies in the UK have the experience and expertise to work in this way and “make things happen”. The cost savings to the client both in time and their need not to have to finalise every aspect of a build project make using Solve 3D and invaluable resource.