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Guest nate

Esu Model Making

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Guest nate

some images of my ESU (medical device) block model i made.

 

 

what i had to start with.

 

i did a clay model so i had something to modify when i got feedback from mentors and teachers etc

 

the foam model was for ergonomics and to use as a template for my block model

 

 

 

at the bottom is the final block model.

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Guest evolve

looks good. I must say, you are making a sweet presentation already with these caption pictures.

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Guest nate

ok with that foam model that i made

 

i divided the foam model into equal sections from the middle, and chose the side i liked the best - because both sides weren't the same i made it in a hurry - so picked one sided and mirrored it.

 

i used the pieces of foam and traced them onto some timber cut the shapes out x2 to get the side profiles

 

 

next i glued the foam model back togeather i plotted out the outline of the esu with a set square onto a piece of mdf cut that out and cleaned it up.

 

i used this outline template to get the outline shape of the product ;)

 

i did this by hot glueing the template to the top of the esu and cut to the teplate on the band saw.

 

you can also see in the pic i cut out some side templates for the profiles of the esu. helps when carving did this like step 1 cut the foam model in sections traced them onto some mdf mirrored and cut out

 

 

 

 

 

next step was to use all the templates and carve out the overall shape.

 

i used a spoke shaver to slowly shape the esu.

 

i used templates to chisel out the pen holder area and the thumb groove.

 

 

next i just sanded the model down to i was happy with the finished

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Guest lufrbasketch

thats a nice method of building up your model. Just out of interest, how difficult was it to create the sections in blue foam? I have tried to use blue foam to build up sections but I always mess it up when I try to match them together.

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Guest nate

hey lufrbasketch

 

the blue foam was sections i glued togeather then carved into the foam model as in the frist image.

 

then i measured and cut the foam model into section with a hot wire cutter

 

 

 

 

so next i used spray primer putty to get a nice smooth finish ready for vac forming.

 

using paper towel to give your model a quick shine helps with the model slipping from the mould.

 

i used a sand bag to lay the esu on as there were to large undercuts.

 

i vac formed the 2 halfs leaving the frist half on when doing the 2nd one as to leave a partline - so i know were to cut.

 

the bottom pic shows the vents i cut into the vac forming - this was done by sticking a template to the backend area and using a dremel to hand cut the sections out.

 

each part that i vac formed i primed and filled ready for painting. :)

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Guest nate

next i cut out the 2nd piece - top half - i then made a template again to cut out the face plate - the white part

 

with the face plate i used car bog to form the snap - just alot of sanding

 

i then used templates to cut the screen etc out primed and painted

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Guest nate

so the finally product is the painted block model - i sanded each vac forming back a little for the partline

 

and i placed the wood model back into the vac formings as it gave a better idea of the products weight the orgional products weight was 3kg this block model was 100g off which is good.

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Guest nate

here are a few more pics i took during the process.

 

as you can see - the foam model i cut in half - i stuck it to an mdf sheet with the edge of the sheet attached to the models centrline. - i cut it with the wirer cutter with the sheet acting as a guide - cause the foam model didn't have a square edge.

 

4 pics down - shows the pencils marks from using the set square and pencil to plot out the outline of the esu - i then cut this out and used it as a template.

 

5 and 6 - shows the sections i cut which i then traced onto the timber sections and then cut out - 6 shows the sections i cut to get the template for the esu's curves

 

last pic shows the vents i cut out with the dremel into the vac forming which has been primed and sanded. i cut a template of the vents out of cardboard. stuck it on and dremeled out the shape.

 

hope these help a little more.

 

see my esu photoshop renderings in the 2d section and finished work sections.

 

will post more soon

 

cheers

nate

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Guest simpson

hi, nice model.

just a simple question. what tools did you use to cut the shape out of foam?

the tools i use just don't seem to be sharp enough... it's pretty hard just making a simple form.

so maybe you use something that you made yourself? thanx.

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Guest sholahskwi

mMan you are awesome,i am a IDD student in Nigeria,and we have been doing quite some work,but mine werent just good enough,but if you can help with tips i will be grateful.Keep it up man.Thanks.

 

Shola.

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Guest monica928

hey, nice model!

 

seems simple but fashionable!

www.peopeo.de

www.peopeo.com

www.conceptostudios.cn

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Guest won-93r

hey nate

nice job man really nice!!

hey you mentioned spray primer putty to smooth out the surface.. wat was the stuff called as in the brand of it bcause it did a reallli good job

cheers :thumbsup:

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