Orange Coast College Students Sculpting the Future with Precision Board

The students at Orange Coast College in Costa Mesa, California, are creating sculptures using Precision Board High-Density Urethane.  It’s all part of Leland Means’ sculpture class.  He’s exposing the kids to materials they may use in the professional world and empowering them to expand their skill sets.  Coastal Enterprises provides Precision Board to universities around the country as part of our donation program.  Our goal is to support the next generation of engineers, artists, architects and designers so they can take the craft to the next level, just like these students at Orange Coast College are doing.

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The assignments for Leland’s 3D design class include enlarging everyday objects and creating electric guitar prototypes.

“It has been a real boon for our students to use a material that they may encounter in the professional world and an empowering experience to be able to create convincing objects using their skill sets.

Chuck Miller, President of Coastal Enterprises adds, “you can tell by the looks on their faces that these students are incredibly proud of their work, as they should be.”

You can view a gallery of past and present student projects created using Precision Board HDU below.

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Orange Coast College‘s 164-acre campus is located in Costa Mesa just minutes from Southern California’s beautiful beaches. Founded in 1947, with classes beginning in 1948, OCC has grown into one of the nation’s largest — and finest — community colleges, enrolling more than 25,000 students each semester.

Orange Coast College features exceptional facilities and the latest in technology and offers more than 135 academic and career programs, including one of the nation’s largest and most acclaimed public nautical programs. Nearly half the students on campus are enrolled in one of OCC’s Career and Technical Education programs.

Coastal Enterprises manufactures Precision Board HDU, a high-density urethane material used extensively in the tooling industry.  It is a closed-cell rigid material that does not rot, warp or crack.

Coastal has a long tradition of donating Precision Board HDU to schools around the country in support of the next generation of engineers, designers and artists working in composites.  If you are interested in finding out more about our Precision Board school donation program, check out our School Donation page and get in touch with us to see how we can help your program out.

UCSD Human-Powered Sub Competes Internationally

We previously showed you how a team of engineering students from UCSD designed and fabricated a unique human-powered submarine as part of their classroom learning experience. Instead of using a rotary propeller, they took a cue from marine life and designed a dolphin fin propeller.  The students then competed at the European International Submarine Races in Gosport, England back in July. Here is a write-up from Tobin Gutermuth, the team captain, about their experience.

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In Tobin Gutermuth’s own words…

As many of you know UCSD HPS made it to the European International Submarine Races for the first time this year. Myself and six other teammates attended the event held at Qinetiq Ocean Basin in Gosport England from July 3rd- July 14th. We stayed in Kingfisher caravan (trailer) park next to the beach in Gosport with race officials and 11 other teams from around the world.

From 9am to 4pm teams would fix, modify, and race their submarines in the amazing Qinetiq Ocean Basin. The pictures do not do the basin justice. Diving and racing in the perfectly still crystal clear water of the basin was such a unique opportunity which we would not have without the generousity of Qinetiq, and the dedication of the race organizers who volunteer their time to put on this fantastic event. It was really amazing to see the fully flooded submarines start off perfectly still, suspended in the body of water (near a half ton of neutrally buoyant mass), then accelerate off of the start line like a torpedo or in our case like a dolphin. The race course was made up of a straight away with a timing trap, u turn, and back through a slalom course.

At 4pm all teams returned to the trailer park. There we got to know the various teams, sharing meals, drinking cheap beer, and hanging at the beach. IMarEST and the race organizers also held several events including a BBQ the first night, a lecture on Submarine design at the Portsmouth historic dockyards, an open house where the teams presented their designs to the public and to eachother poster board style, a tour of the Royal Navy Submarine Museum where we got to walk through the HMS Alliance, the only remaining WW2 era submarine (a real highlight of the trip), and a talk on deep ocean exploration.

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On the last Friday of competition everyone attended a black tie event at a hotel in downtown Portsmouth with three course dinner and open bar, how the British Royal Navy does it. Before dinner we had an award ceremony. Vaquita got 7th place out of the 12 submarines. The judging was based on Design Report, Dry Inspection (where the quality of our design and build were judged), Wet Check (where each team had to demonstrate their pilot Safety Buoy function and pilot escape underwater), Race Performance, and Reliability. Unfortunately the performance and reliability of our submarine was severely impacted by a poor choice in buoyancy foam. The foam we used compressed at depth in the ocean basin. So, even though we were correctly trimming the submarine at depth, as soon as the depth changed (i.e. the submarine coming closer to the surface), the foam expanded and made the submarine increasingly buoyant, sending our sub up to the surface. We failed to notice this design flaw during testing because we only went a short distance in the school pool and the pilot stayed at a relatively constant depth.

Nonetheless, we still managed to cross the finish line four times, albeit at the surface. All the other systems in the submarine (drivetrain, steering, safety) were functioning normally. While we couldnt see the full potential of our propulsion and steering systems, we were glad to have completed several races at EISR, including navigating the slalom course. While we wish we could have performed better, we know that this project is really about learning and we certainly learned a ton this year.

Vaquita was also awarded with the most unusual design award. Of the 12 submarines there were only three non propellor subs. The other two non propellor subs used Hobie Mirage drive propulsion systems. We received a lot of enthusiasm from the judges and other teams about our unique design.

ucsd

The spirit of the races is all about camaraderie, having fun, and learning. Teams shared tools, divers, and tips/experience about how to improve subs, manage teams, and fundraise. We are a small community of human powered sub engineers. I hope that UCSD will attend the European races for many years to come. Next year the team will be lead by 3rd year Xander Westra, the propulsion lead from Vaquita. The team will likely reuse the same hull and focus on building a stronger team mentoring new members by having them improve existing systems. The team plans to attend the submarine races at in Maryland next summer.

Big thanks to all our corporate and school sponsors this year:

UCSD Jacobs School of Engineering
American Society of Naval Engineers, San Diego Section
American Society of Mechanical Engineers, San Diego Section
UCSD Mechanical and Aerospace Eng. Dept.
UCSD Structural Eng. Dept.
Northrop Grumman
SunRez
Oceanaero
Coastal Enterprises
UCSD Structural Engineering Undergraduate Development Labs
UCSD MAE Machine Center
UCSD Visual Arts Department
Triton Engineering Student Counsel
UCSD Drone Lab
Lormac Plastics
Teledyne Seabotix
Aeromarine
UCSD Envision Makerstudio
Revchem Composites
Fiberlay

Coastal Enterprises manufactures Precision Board HDU, a high-density urethane material used extensively in the tooling industry.  It is a closed-cell rigid material that does not rot, warp or crack.

Coastal has a long tradition of donating Precision Board HDU to schools around the country in support of the next generation of engineers, designers and artists working in composites.  If you are interested in finding out more about our Precision Board school donation program, check out our School Donation page and get in touch with us to see how we can help your program out.

You can read part 1 of this blog HERE where they describe the process of using Precision Board HDU to create the molds for the submarine.

Using X-Edge Router Bits to Maximize your CNC Machine

Do you want to maximize the capabilities of your CNC Router without breaking the bank?  According to X-Edge Tools, as technology has advanced, CNCs have become faster and more efficient but router bits haven’t changed much.  Instead of simply following the old chip load calculator and calling it a day, X-Edge Tools decided to design, test, re-design, test and repeat until they achieved the absolute best balance between speed and cut quality.  We asked them to test cut Precision Board HDU and see how fast they could rout it without degrading the edge quality.  They cut our material at feeds from 300-1000 inches per minute (IPM) and speeds of 18,000-22,000 rotations per minute (RPM). What follows are speeds & feeds settings for milling a variety of Precision Board HDU densities using the latest cutting-edge router bits from X-Edge Tools.

From the X-Edge Router Bit Team:

Here are the tools that we used and the associated feeds and speeds for routing a variety of Precision Board HDU densities, including PBLT-15, 18, 30 and 40. Machine used was a MultiCam APEX3r.

  • Roughing- XB2072 Ball Series 1/4″ Ball nose 800 Inches per minute @ 22,000 RPM
  • Carving- XCT018 Carving Series 1/8″ Tapered Ball nose 800 inches per minute @ 22,000 RPM
  • Engraving- XV2006 V-Groove Series 60 degree V groove engraver 300 Inches per minute @ 18,000 RPM
  • Cutout- XR2063-CB Razor Series 3/8″ diameter 2 flute slow helix with chip breaker 1000 inches per minute @ 20,000 RPM.

“We could not find a speed fast enough that would begin to show a degrade in cut quality with this tool on your material,” says Leslie Dowson, Director of Sales and Marketing. “You could cut as fast as you want and it did not begin to tear out the material or anything,” she added.

Jim Dawson at Synergy Sign in Ohio uses X-Edge router bits to cut Precision Board HDU.  “Our machine cannot outrun the material,” says Dawson.  “We run 400 IPM at 14,000 RPMs and could run it way faster.”

You can watch videos of Precision Board HDU being routed by X-Edge bits on our YouTube Channel.  There are videos for PBLT-15, 18, 30 and 40 in the routing playlist.

X-Edge is located in Grand Rapids, Michigan and manufactures CNC router bits and accessories.  Their tooling was designed specifically to maximize the capabilities of CNC Routers.  eXcellent speed, eXcellent quality, eXcellent tools.  You can call them at (224) 534-9653 or visit their website.

Coastal Enterprises offers free samples of Precision Board HDU.  Already have a project in mind for our material?  Request a quote and get started today.  Sign up for our monthly blog roundup so you don’t miss any of our informative blogs.  Have a special project fabricated with Precision Board HDU and want to know if it could be featured in a blog on our website?  Give us a call at 800-845-0745 or drop us an email with details.  We’d love to hear from you!

The Secret to Creating a Neat Glued Joint on Precision Board

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to announce a series of guest blogs written by Dan Sawatzky of Imagination Corporation, which are posted on the Precision Board Blog each month. This month Dan Sawatzky lets us in on a little secret of his when it comes to gluing Precision Board HDU- when he wants a smooth bond-line, he’ll glue the pieces together first and then rout the material.  He gives us an example from his latest project- The Hazelnut Inn fantasy suites.

glued

In Dan Sawatzky’s own words…

A comment I often hear is how layers of glued Precision Board need a lot of edge finishing prior to paint. When folks use PB Bond 240 or PB Fast Set it often squishes out between the layers as it cures. In our work this isn’t often a problem as we texture the edges of our work, most often with an air powered die grinder. It is quick work and adds a lot of value to the finished piece.

But occasionally we need a neat glue joint as we layer up the Precision Board within the edges of our work. I’ve found the easiest way to do this is to glue up the board before we do the routing. It’s a great way to use up smaller pieces of Precision Board and it saves using a whole thick board and turning the bulk of it to chips and dust.

Precision Board also offers custom cut and glued up blocks for your larger projects!

I have a small project in the works that is a great example. It’s a tribal mask for the Hazelnut Inn decor. I went through our scrap pile and selected three pieces of 1” thick material, making sure they were slightly larger than necessary. I then glued and screwed them together. Because the top layers were a bunch smaller than the bottom, the clamps wouldn’t reach. Once the piece had cured, I removed the screws (hitting a screw with a router bit is rather hard on bits).

glued

I threw the piece on our MultiCam 3000 CNC router and ran the job in two passes using a 3/8” bit for the rough and a 1/8” tapered bit for the final.

When the piece was finished I glued a fourth layer of 1” thick Precision Board underneath for extra thickness.

I then used our air-powered die grinder to extend the woodgrain down onto the edges. The piece was now ready for paint.

I measured up some rope we had left over from a recent project and then drilled the bottom edge with a series of holes. These were to accept the rope segments for the beard. I used hot glue to fasten them into place.

I then applied the glazes to bring out the woodgrain. Then the green, red, orange and white was carefully dry brushed on the ridges of the woodgrain. Then I unfurled the ropes and spread out the single strands to form the beard on the mask. The final result looked better than I imagined when I did the design! Some mounting hardware will make the mask ready to hang in the room.

Local lore holds that the North Star Suite of the Hazelnut Inn was once the home of an eccentric explorer, who gathered artifacts and curiosities from every mythical corner of the world and built her estate around them. There will be a whole bunch of ‘artifacts’ of every description on display in the room when we are done. Here’s another piece which we recently completed. The mounting board is made from 30 lb Precision Board.  Stay tuned for many more…

glued

Sawatzky’s Imagination Corporation is a small family company that specializes in the design and creation of dimensional signs and environments. They tackle projects of any size from small signs to entire theme parks. Their work has garnered numerous national and international awards.

Dan Sawatzky is best described as a creative force and visual storyteller extraordinaire. His art career spans almost fifty years of magic. Dan’s passion is to design and create imaginative places that take people from the normal world to a setting of delight and wonder.

Coastal Enterprises manufactures Precision Board HDU, a versatile, cost-effective and eco-friendly urethane sign material that is particularly effective for making professional-looking indoor and outdoor dimensional signs.  It is a closed-cell rigid substrate that does not rot, warp or crack.  You can request free samplesget a quote or sign up for periodic newsletters packed with helpful information.

Fabricating the Amish Country Sign with Precision Board, Steel & Concrete

When Jim Dawson with Synergy Sign was asked to design and install a sign for his client’s new luxury hotel, event center and Amish Country Theater complex, he knew it had to be big enough to draw attention from nearby State Route 39. At 24’x24’x4′, the Amish Country sign ended up being the largest sign Dawson had ever built.  He used steel, concrete and Precision Board HDU to accomplish this huge task.  Read on to find out how Jim and the team at Synergy Sign constructed the Precision Board HDU part of this behemoth sign.

precision board

Six signs in total were routed from PBLT-18 Precision Board HDU, with three for each side of the frame.  Two signs were 4’x14’x1″ and one was 3’x14’x1″.  Jim routed wood grain texture into the signs and then made a 45 degree bevel around the letters to give the illusion that they were popping out. The Amish Country green background was done with a second layer of 1” thick Precision Board.

Jim and his team created galvanized steel boxes that were 6″ wide and screwed and glued the Precision Board signs to both sides. He used the same steel beams and fabricated mounts for the LED sign.

Dawson says, “the bands on the posts that look like steel straps were actually made out of PBLT-30 Precision Board.”  He adds, “giant oversize rivets were cut into a dome on the router and we used 4 inch thick PBLT-18. Then we made them faceted by grinding them into the surface with our sanding bench.”  Jim attached the rivets to the “steel straps” to complete the look.

precision board

Dawson used several different paints for this job, including Novacolor metallic paints for the straps, Sherwin Williams on the concrete and Kemiko paint on the sign faces.

Design to completion on the Amish Country sign was six months with about three days of routing time for the Precision Board HDU on their MultiCam 3000 CNC using X-Edge router bits.  Jim says, “we had twelve 4’x8′ sheets of Precision Board that would have needed to be carved.  Because it would have taken 15-16 hours per sheet to carve in 3d, we instead used the Rapid Texture feature in our Enroute Software.” (Ed note: You can read more about Rapid Texture HERE) Jim says it made sense to do it that way given that the texture didn’t need to be super detailed, it just had to look good from a distance.

Jim wrote a lengthier article for the October issue of Signs of the Times detailing the entire fabrication process, including creating the steel posts. That article can be read HERE.

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We think that Jim Dawson and his team do some really excellent work. Synergy Sign & Graphics has a highly experienced staff whose backgrounds include graphic design, marketing, trade-show design, print media, branding, point of purchase design, fulfillment, and more. Check out their website or give them a call at (330) 878-7646 to see about your next project!

Coastal Enterprises offers free samples of Precision Board HDU.  Already have a project in mind for our material?  Request a quote and get started today.  Sign up for our monthly blog roundup so you don’t miss any of our informative blogs.  Have a special project fabricated with Precision Board HDU and want to know if it could be featured in a blog on our website?  Give us a call at 800-845-0745 or drop us an email with details.  We’d love to hear from you!

You can view a wide selection of in-process photos below from Synergy Sign’s fabrication of the Amish Country sign.

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