Solve3D - GMC Hydrogen powered drill

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 acrylic. 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 located on the same site.

Filled 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 and then with technical nickel, to represent aluminium pressure die castings. This process took 54 hours from start to finish, some 2-3 weeks faster than the quoted lead times to produce a lost wax pattern and receive final aluminium castings from a foundry.

The main charger frame had to represent the look and cold feel of brushed stainless steel and contain the deep embossed logo of the company. A high density epoxy model board was machined and fabricated to for 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 was a unique and successful blend of cutting edge rapid prototyping technology and traditional model making, oh and a large measure of black art!

A unique solution for a unique product.