Fifty ways to build a relief – Part six

For our sixth version of the fish relief I did not start at the beginning. The chamfered edge relief with the sunken center was already done. To see the previous steps go back and review the fourth installment of this series.

This time we would be using bitmap textures. The ones I am using are from my TEXTURE MAGIC collection. There are one hundred and five textures on the disk – plenty to choose from. Here’s a sampling. To get information about purchasing this collection go to TEXTURE MAGIC COLLECTION

The first texture I used is called ‘chicken scratch’ Keep in mind that black areas of the bitmap will do nothing. White will raise by whatever value you choose. Grays will do something in-between. Chicken scratch is black and white so the results will be pretty dramatic with sharp edges. When I open the bitmap, by default it sizes to the edge of my plate.

Since my file is relatively small I need to make the bitmap substantially larger for my 1/8″ bit to fit into the grooves of the pattern we will create. To access the apply bitmap menu I need to select my relief and the bitmap. I selected AD TO, entered a value of 0.15″ and then hit enter. In an instant the bitmap texture was applied to the relief.

Then I opened another texture (one of my favorites) called SPLOTCHES and went through the same procedure, first making it bigger and then applying it to the relief. This time I entered a value of 0.1″ making the texture a little more subtle.

In the next few steps I built a flat relief using the fish outline, then domed it up and merged it to the base relief. These steps have been covered previously in this series.

I then used the fish vectors and prism tool to add the fish to the relief. (also covered previously in this series) Then it was time to add the ‘SPLOTCHES’ texture again but only to the fish this round. I opened the splotches bitmap, selected it, the fish vector (it will act as a mask) and the base relief, then opened the apply bitmap menu. This time I wanted the texture to be subtle so I entered a value of 0.1″ and then hit apply.

 Then I created a rope mesh once more using the extrude function. This was nudged into its proper place vertically and then MERGED highest with the base relief. This was covered in a previous post in this series.

 Next time I’ll be tool pathing the last two files and getting ready to send them off to the multiCam. Stay tuned…

-dan

Published with permission from precisionboard.blogspot.com. Source.

Trains!

I’ve loved steam trains for as long as I can remember. They just have a magic about them. I’ve panted a bunch of historical murals that featured them and have studied endless historical photos to get the details just right. Instead of building small scale model railroads I have fun building larger scale trains in a cartoon style.

The first train I built was about thirteen years ago. It was for Giggle Ridge Adventure Golf. The train was largely built from welded steel and was a static display and sign.

Nine years ago I started work on the next train – one that would travel around our property. It is dubbed the ‘grampa train’. It’s not quite done yet, put off by the construction of our new house, but one day soon we’ll be riding in style!

Just after we purchased our MultiCam six years ago it was time for another train. This one was for a display piece and sign for an Adventure Golf. The golf was at the Mall of America in Minneapolis, Minnesota. The special challenge this time was to build a train that looked like many tons of steel but actually lightweight materials because it was to be part of the golf on the third floor.  Much of the train would be routed from Precision Board.

The pieces are glued up over a welded steel frame. Many HDU components were substituted for the real thing, all routed in detail by the MultiCam. It only looked heavy.

 Certain parts were steel but they were light gauge. As we worked I painted the parts with an iron paint and then sprayed them with an oxidizer creating instant rust.

Hundreds of parts were designed in EnRoute and cut on the MultiCam from 30 lb Precision Board. This made everything still very strong but lightweight.
Amazingly, with the help of EnRoute and our MultiCam this project went from design to ready to ship in only ten days!

Today I started design work on yet another train. It also will be a static display and sign for another Adventure Golf. The theme will be logging once more. I first dug into the local history and found that in the early days of this community they used a Shay Locomotive to haul the logs out of the woods. This would be the starting point.

Like the others the train we would build would be about half scale vertically but drastically shortened horizontally to give it a quaint cartoon style. I sketched my ideas in my sketch book and then scanned it into my computer to do the final rendering. I used my Wacom digital drawing pad to draw freehand, using my initial sketches as a guide. In a couple of hours I had the plan in hand. Like the train for Mall of America, we’ll route many of the detailed components on our MultiCam from Precision Board. All of the files will be built using EnRoute of course. It will be a while before we physically start the project but you can bet you will be able to follow it step by step here.
Stay tuned…
-dan

Published with permission from precisionboard.blogspot.com. Source.

Primal 2 – 70 MPH of Engineering Innovation

There are some who simply work in the mechanical engineering field and others who do not just work in it, but have a passion for it. In the case of George Leone, whom many of you may remember as the Technician in charge of the Cal Poly Hangar Shop, its clear he has a passion for all things mechanical.

Several of our previous stories have covered George and his involvement with Human Powered Vehicles, Supermileage cars and SAE race cars. Well, George recently contacted us about a “side” project he completed and entered into the Boca Bearings 2012 Innovation Competition: A human powered vehicle known as Primal 2 that was built entirely at his house. Grand prize for the Boca Bearings 2012 Innovation Competition is $10,000.

Check out this video about Primal 2, and be sure to vote for the best entry in the Boca Bearings contest as well!

George says if they win the proceeds will be split evenly between Verant Chan, maker of this video to help further his filmmaking career, and the construction of Primal 3, which George hopes will be able to reach 85-90 mph!

Primal 2 was built in the 30′ x 60′ barn George converted into a workshop next to his house. Alongside George, several current and past students, and professors from Cal Poly also helped build Primal 2. The ultimate goal was to achieve the highest miles per hour possible, which meant it needed to be as aerodynamic and efficient as possible while also maintaining a high level of safety.

To make the aerodynamic body, George used Precision Board Plus PBLT-4 and hand shaped a plug for the car body. It was shaped on a custom made rotisserie fabricated from two Harbor Freight engine stands. The plug was then sprayed with Duratec to make a mold for the car body. Finding that the initial body was not as aerodynamic as they liked, Duratec was sanded off of the existing plug and more PBLT-4 was added to alter the plug. The resulting changes in the body shape led to a 4 mph increase. Car body is fiberglass exterior, kevlar interior with 6k carbon bands for stiffening. Divinicell ribs wrapped in carbon post-bonded and covered with kevlar provide extra strength. Chassis is chrome moly steel tubing built by Dan Baggs a local San Luis Obispo frame builder. Primal 2 also has a 5-point racing harness and a rollbar.


Primal 2 was completed in a record 51 days. Most human powered vehicles take an average 2 years to complete! A lifelong surfer, George has lots of experience shaping surfboards which helped him develop the fiberglass skills he attributes to the quick finish of Primal 2. The highest speed it reached was 70.4 miles per hour, and it has crossed the 70 mph line on 3 separate occasions. Pretty impressive for a vehicle powered entirely by the human body!


George Leone has been involved in all things mechanical since 1980, volunteering after attending a presentation where several students needed help building a fiberglass car body. Between 1984-1988 George and several other friends completed the worlds first all composite bike. Since then he has grown quite fond of the Human Powered Vehicle concept and has been involved with many teams in years past. His wife, Carole Leone has even been President of the National and International Human Powered Vehicle associations.


Part of the Primal 2 build team: (left to right) Dave Pocock, Carole Leone, Tamaki Layman, Ron Layman(driver), John Pocock (crew chief) and George Leone.

Cal Poly Professor H.P. helping build Primal 2 in George’s shop.

Fifty ways to build a relief – Part five

For the next version of the relief we started where we left off yesterday.  To begin adding to that version I created a small circle vector and then duplicated it three times. I aligned then using the various ALIGNMENT tools, making everything accurate.
I resized the circles to fit in-between the second and inside ovals.
Here’s a closeup of the circles all lined up nice and even.
Then I used the WELD JOINED tool to unite the circles into one relief.

I opened the EXTRUDE CONTOURS menu and then selected the create mesh button. In the boxes I asked for 200 slices and 200 stacks. This is much higher than we need but it is a habit I’ve gotten into as it creates a very fine mesh. Modern computers can handle this size file really easy and EnRoute’s render engines also redraw them instantly. I asked for eight revolutions as it created the mesh around the oval. I’ve used this tool so many times I had a pretty good idea of what would look good on this size of relief. This will take some experimentation to get good at. Then I followed the prompts in the box. First it asked me for the contour I wanted to extrude. I selected the cross section of the rope.

 Then I was prompted to I selected the second from last oval, then pushed the green apply check mark..

 In an instant EnRoute generated the rope. It shows up black.

When I hit the render button the rope mesh appears red. I dropped down the the front view and because I had aligned the original relief to the bottom of the plate the rope floated above it.

When I selected the rope mesh it turned green.

 I used the down key to nudge it into position, just a tad higher than half way into the base relief.

To get the APPLY MESH TO RELIEF button to become active I had to select both pieces. I opened the box and selected MERGE HIGHEST… then hit apply.

In an instant the mesh shape was applied to the base relief. When I hit render bits of yellow peek through the red mesh. This tells me everything is peachy keen. The mesh is still there, unaltered. I can either delete it or move it to an inactive layer.

This version of the fish plaque is now complete and looks extra snazzy.

 Tomorrow we’ll begin once more creating a new version using bitmaps for texture.

-dan

Published with permission from precisionboard.blogspot.com. Source.

Chainsaws and Jelly Beans: New West Hollywood Library Sculpture

Jelly Bean Sculpture

Carving a sculpture out of Precision Board Plus with a chainsaw is no easy feat. Meet Cosimo Cavallaro, artist, sculptor, and film director. Cosimo is in the process of making some rather large jelly beans using Precision Board Plus PBLT-4 as a plug. The four oversize (5’ x 5’ x 10’) jelly beans are destined for display at the West Hollywood Public Library.[divider_padding]Precision Board Jelly Bean 1

Starting out with a large, custom-bonded block of Precision Board Plus PBLT-4, Cosimo carved the rough shape of the bean out using a chainsaw. Next, a surform, or rasp was used to smooth out the rough edges. The entire bean was then sanded with 36 grit sandpaper for a smooth finish.

Precision Board Jelly Bean 2

Next step in the process will be to cover the bean with fiberglass in preparation for making a 2-part mold. This will enable him to make 4 identically shaped jelly beans without needing to carve each one with a chainsaw. Once the molds are complete Task 15 Liquid Performance Plastic will be poured into them and the two pieces will be allowed to cure. They will then be removed, joined together and painted with vibrant acrylic paints. They will end up turning out as real looking as some of the smaller jelly beans he has made in the past (see left image below).

Precision Board Jelly Bean 3

Cosimo Cavallaro is renowned for his off the cuff art projects and has been featured in galleries and museums worldwide.  You can check out his website to see some of his famous projects. Next month, look forward to seeing pictures of the moldmaking and paint process as Cosimo continues this project.[divider_padding]Precision Board Jelly Bean 4