We like big blocks and we can not lie…

We have a lot of action going on here this week! Making custom blocks is something we take pride in and is one of the great things that separates us from our competition. It only took a couple of days and two forklifts to get this 19 footer out the door.

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PBLT-15

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PBLT-15

Our team has been bonding blocks for over 20 years and tight bond joints are our specialty. Using our EP-76 high strength machinable epoxy, and adding PB granules, we’re able to match the density of the material which allows for ease of machining and the ability to keep the CNC  running fast.

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PBLT-15 Bonded Blocks

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PBLT-15 Bonded Blocks

It’s great that customers take advantage of our one-of-a-kind service. Custom bonded blocks save extreme amounts of time and money by arriving on the job ready to machine immediately.

A Wrap Fit for Kings

Cheesy I know but I had to say something.  Spring is almost here and we are wrapping like crazy over here – the first of Kings Supermarkets fleet has just been completed and ready to hit the road. Great job Rad and Greg! – Steve

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Published with permission from KDF Custom Graphics. Source.

Awesome mesh tool

EnRoute has many cool tools that can be used individually or together with other tools to create anything I can imagine – and that’s a lot. Last week I was building some faux hydraulic cylinders for a display and the mesh tool proved to be the simplest and quickest way to get exactly what I needed in a hurry.

The cylinders are a small part of the MultiCam display for their booth to be held at the International Sign Association trade show in Las Vegas next month. This is the TV stand which I will use for my presentation.

I started with hand drawn artwork as per my usual. This artwork defined the basic look of the finished piece but did not lock down every detail. We always get better ideas as we proceed.

The original thought was to fasten the vertical piece to the backdrop the client would provide but as I set about beginning the build we decided to include a horizontal base so it would stand on its own. To make it a little sturdier some angle braces on the bottom were in order but they couldn’t merely look like angle braces. We decided to camouflage then as hydraulic cylinders in true steampunk style. For an extra bit of fun I added Kris Co embossed into the cylinders – a nod to my friend Kris Hanchette, president and general manager of MultiCam.

All of the necessary vectors were drawn in EnRoute with the drawing tools including the rectangle around the piece.

The first step was to use the rectangle to create a zero height relief.

 I then selected this relief before opening the mesh creation tool. In this fashion the mesh tool is used to modify the relief rather than creating a mesh shape alone. The menu takes you through the procedure easily.

In a few clicks I had my cylinder shape. The next step was to add the flat flange which would protrude out of the bottom of the cylinder.  I would build it as a separate relief.

This separate relief is then merged highest with the base relief.

I now had half of a cylinder. I duplicated it and then created the lettering we would emboss into each side. I duplicated the lettering vectors before flipping one 90 degrees (so they would read the same way no matter which side you read) 
I positioned these letter vectors on the cylinders.
Then I modified the reliefs by subtracting from the reliefs using the lettering as a mask.
I made two copies of each side because we needed two cylinders. then I sent the files to the MultiCam to be routed from 2″ thick 30 lb Precision Board. They were fitted over the 1″ pipe braces. Other smaller pieces were fit around the end flanges to build convincing attachment points in mere minutes.

Then I fitted on all of the PVC conduits with custom routed brackets. Some domed rivets were also routed and then glued onto the back board. It looks very industrial and steampunk in a hurry. The paint will add a lot  in the next days.

Two of the three pieces are nearing completion. Stay tuned to see the finished results.
-dan 

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

A Trip to the Police Station!

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Don’t get the wrong idea. KDF is honored to have been chosen by the great Borough of Northvale, NJ to create some custom signage.

Here are some of the signs before they go out the door for install.  We used Precision Board HDU, both 15lb and 30lb,  and cut the relief of the patch with a 1/6″ Ball end mill on our MultiCam 3000 CNC.  Everything was painted  with Modern Masters Metallic Paint.

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Published with permission from KDF Custom Graphics. Source.

Hand Shaping HDU made simple with Precision Board Plus

The Concrete Canoe Team of Chico State University was determined to build a mold out of high-density urethane this year when they found Coastal Enterprises Company through their competitors at University Nevada Reno Concrete Canoe. They initially intended to go with a mold design that would be CNC machined. However, due to changes in design they ran out of time and were forced to hand-shape their mold.

Foam 1

PBLT-10, PBLT-15

Foam 2

PBLT-10, PBLT-15

 

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PBLT-10, PBLT-15

Foam 5

PBLT-10, PBLT-15

Foam 8

PBLT-10, PBLT-15

They were a little apprehensive at first having never worked with high-density urethane before. “We weren’t sure exactly how smoothly it was going to go, but once we started to work with it, we loved it! The Precision Board cut easily and was insanely workable. Using only hand tools, rasps, and files the results were smoother and more streamlined than we could have ever hoped for.” Chico State Team Member Kaylie Humbert said.

“The canoe project itself took months, however the Precision Board mold that we created only took a single day. It was so easy to work with I would absolutely recommend it. None of the team members had any experience working with Precision Board before and as beginners we were very pleased with the results that we were able to achieve. I can only imagine what professionals would do with it.”

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For more information check out Chico States Concrete Canoe Team.