Architectural Ceiling Design for American Girl New York

When American Girl wanted a unique architectural ceiling design for their new store in New York, they got in touch with Moss Retail and Environments who, in turn, contacted Jim Dawson at Synergy Sign and Graphics.  He consulted on the design and mounting for about six months and once the designs were approved, Jim got the go ahead to make this creation a reality.  Dawson fabricated the design out of large sheets of Precision Board HDU at his shop in Ohio, which were then broken down into smaller, shippable pieces that were sent to New York and then reassembled.  We talked to Jim to get some tips on the architectural applications of Precision Board as well as how they mounted the intricate designs on the ceiling.

architectural

“We used PBLT-18 in both 2 inch and 3 inch thicknesses,” said Dawson. “These shapes were cut from several large sheets of Precision Board from 4′ x 8′ up to 5′ x 10′,” he added.

Synergy was sent auto cad drawings of the ceiling and the individual profiles. They used Enroute Pro and nested everything to cut out the individual pieces. There was a “Part A” and “Part B” which resulted in the fabrication of a lot of small pieces- 60 of one part for example.

Dawson said, “For the large complicated petals, we cut the 10′ by 10’ designs in half so the pieces were smaller for shipping and then reassembled. Installers used Bondo to reattach them after shipping and then touched up the seams.

It was at this point that the individual pieces of Precision Board HDU had to be mounted to the ceiling.

When Moss and Synergy designed the pieces, they wanted an install method that would be completely hidden and wouldn’t need a ton of touch up in the field.  PBLT-30 Precision Board pucks were created that were attached to the ceiling via screws and zip toggles.  They routed corresponding pockets in the backs of the petals so the pucks could drop inside.  The petals were then glued to the ceiling using fast set epoxy.   It made for a completely hidden mounting system.

One small issue that Dawson had was finding a bit that they could use to cut the material. “We did a lot of testing because it’s hard to find bits long enough to cut 3 inch material. We did speeds and feeds calculations and it turned out that one of the cheapest bits we bought worked the best.”  Jim used a ½ inch diameter x 5” long four flute low-helix spiral bit from Hartlauer that was classified an end-mill. He spent $25 on it.

The entire project took three days of routing and 4 days of finishing / packing and was shipped in just short of 1 week.

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!

Chuck Miller, the President of Coastal Enterprises, was recently in New York and stopped in to the American Girl store to snap a photo of how the ceiling looks with a store full of happy customers.  Check it out!

Check out our Precision Board architectural ceiling design at the 1:27 mark in this video released by American Girl about their NYC grand opening.

You can get large sheet sizes of Precision Board HDU up to 5′ x 10′ in any increment from 1/2″ up to 24″.  Get a quote or request free samples today to see if Precision Board is right for you.  We’d love to hear from you!

Faux Wood Grain Texture Using Precision Board HDU

There’s something nostalgic about a wood sign, so it’s not surprising that people want to have signs that appear to be made out of wood, but without the drawbacks- rotting, warping, or deteriorating. Brian Quinter of Quint Creative Signs has created so many faux wood grain textured signs from Precision Board HDU that it’s become almost second nature.  They even have names for it- ‘Basic Wood Grain Texture’ and ‘Super Realistic Wood Grain’.  Quint Creative has fabricated hundreds of signs that look like wood and dozens with the Super Realistic Wood Grain. We talked to Brian to get some tips and tricks for making faux wood signs from Precision Board HDU.

faux wood

Brian Quinter first started making faux wood signs seven years ago that looked like sandblasted wood signs.  That changed when a job came to him about four years ago for The Barrel House. They wanted something that looked like an old sign that may have been found in a barn with deep wood grain and a natural wood finish. That was when he started making the Super Realistic Wood Grain textured signs.

To achieve their super realistic wood grain Brian uses Vectric Aspire. He creates 3D components from two different bitmaps of wood grain. Brian often finds a texture first on the internet and uses it to create a 3D Component.  The second he creates using Corel Draw, which he converts to a bitmap and edits in Corel Photopaint.  He uses an Eye Candy plugin to make his grains look how he wants and then creates a 3D Component. Brian then bakes both textures together as one 3D component and finishes the design in Vectric Aspire. He uses a 3D Finishing toolpath with a .25 Ballnose bit.

“I usually include elements like knots and often bring the texture and faux painting onto the framing of the sign. I find having some machining lines help make it look even more like wood when we do the glazing after we paint it,” said Quinter.  “I do basic textures using Aspire’s Texturing Toolpath tool, but I like to do Full 3D wood grain for the higher end signs,” he added.

Brian prefers Precision Board HDU over actual wood because he can control what he makes.

“If I’m using wood and trying to expose the natural grain, I don’t know what I’m going to get. If I hit a knot, it can mess me up.”  He added, “I can deliver what I’m designing without worrying about problems during fabrication and my client gets what they have been shown in a proof.” (Ed note: the above photo is an example of a proof- the one that Brian showed to Hawk’s Nest)

Hawk’s Nest is his most recent faux wood design for a sign.  They were looking for rustic, so they wanted something that looked like wood instead of going with flat plastic or aluminum.  The sign was fabricated using PBLT-15 that was 1.5” thick for the background.  The letters were also made out of PBLT-15 and were 1.5” thick. Nova Color paints and glazes were used for the entire project, including the metallic silver and gold.

Brian used convex letters to give the sign some highlights and shadows. If you look at the letters, the sides are painted black and the front is painted the main color for the letter.

“There’s a lot of little touches that help bring it together that may not be noticed by the normal person,” says Quinter.

Brian has some advice for those just starting out with faux wood signs.

“The hardest thing is color choice when you start painting it. Some of that is experimental to achieve the wood look.” He added, “Prime it. Give it a base coat with a mustardy color. Glaze it and then wipe it off to give it highlights. Start with lighter and work to darker colors. Textures also help when glazing and leaving some of the darker colors of paint set in the texture”

Quint Creative just recently did another faux wood project for the local park system.

“We just replaced some wood signs for Tipp City Parks that were faded and deteriorating and used Precision Board HDU made to look like wood,” Brian added.

The signs were rotting and the client wanted them updated with something sturdy and weather-resistant. The results speak for themselves!

In the end says Quinter, “going with a faux wood textured Precision Board sign will give you a classy, traditional sign that stands out and lasts forever.”

Quint Creative Signs creates one of a kind signs that help set any type of business or organization apart from others. With attention to detail and knowledge of what really works in sign design, QCS signs get noticed where ever they are installed.  Give them a call at (937) 615-9332 or visit their website.  You can check out a lot more photos of Brian’s faux wood work in galleries here and here.

Make sure to sign up for our monthly Blog Roundup to get more content like this sent to your inbox for reading when it’s convenient for you!  Request free samples of Precision Board HDU or any of our companion products, including adhesivesprimers and coatings.

SEE ALSO:

Using EnRoute Software’s “Rapid Texture” on Signage

HDU Vs Wood Signs

Cold Jet Dry Ice Cleaning of Precision Board Tools

Are you considering dry ice cleaning of a Precision Board HDU tool, but not sure if it can handle the pressure? We had Cold Jet, a pioneer in dry ice blasting and global expert on dry ice technology, dry ice blast a PBLT-70 tool coated with FSC-88 WB Primer.

The results? Dry ice cleaning removed the primer and left the Precision Board HDU surface smooth and with no visible surface deterioration.

The test replicated cleaning contaminants off of a fouled mold without damaging the material, allowing for multiple cycles of cleaning and resealing of a Precision Board tool. Read on for technical settings and comments from Cold Jet on dry ice cleaning of a Precision Board tool.

dry ice cleaning

Dry ice blasting is similar in concept to sand or water blasting, but dry ice blasting uses non-abrasive media in the form of recycled CO2 pellets that will not damage surfaces. The combination of dry ice blasting’s kinetic energy and thermal effects break the connection between the contaminant and surface, lifting it away. Unlike blasting with other media, dry ice does not leave any secondary waste, because the dry ice particles sublimate upon impact – converting from solid to gas.

Dry ice cleaning can help meet strict industry demands by providing a composite tool cleaning solution that is fast, delicate and does not use chemicals or solvents. It is a non-abrasive cleaning solution that extends the life of molds and equipment by eliminating the need for harsh chemicals, wire brushes and coarse pads.

Tooling used for, but not limited to, compression molding, resin transfer molding, extrusion, pre-pregging and wet-layup are all exceptional applications for dry ice blast cleaning.

Testing was done on a sample of Precision Board PBLT-70 partially coated with FSC-88 WB Surface Primer. Cold Jet used the i3 MicroClean, with conventional block dry ice, MC88 nozzle, and 60 psi blast pressure.

According to Steve Wilson, Director of Global Business Development for Cold Jet, “the contaminant on this sample required a little less pressure than the uncoated sample of PBLT-75 that we also tested, but could be dialed in to clean quite nicely.” While it cleaned a bit slower than the second sample, the process can be adapted for larger nozzles with the SDI Select-60 machine from Cold Jet.

“The blast pressure is on the very low end of the process capabilities,” said Steve. “There is plenty more cleaning capacity if needed. From visual, 400X photos and calibers, I can see no deterioration to the Precision Board sample surface.” Steve added, “about 2/3 of it has been cleaned so that you can see the comparison between before and after. The surface of the part still feels very smooth.”

BEFORE (400X magnification):

AFTER (400X magnification):

Testing on the second sample of Precision Board, PBLT-75 with no coating was also done with Cold Jet’s i3 MicroClean machine, using the following settings: conventional block, 80 psi blast pressure, MC88 nozzle, 0.6 lbs./min. federate, 2” stand-off distance, 3-4”/sec. traverse rate.

With more than 30 years of experience dedicated to dry ice blasting technology, Cold Jet has unparalleled experience in developing and recommending dry ice solutions to match any need. Cold Jet offers the widest selection, most reliable and most dependable Dry Ice Blasting Systems, Dry Ice Production Equipment, Engineered Systems, and Nozzles on the market.  Visit their website for more information or contact them to get more information about HDU tool cleaning.  We thank them for taking the time to test our material and recommend them for dry ice blasting of Precision Board HDU tooling.

With its roots in Aerospace, Precision Board Plus HDU Tooling Board is specifically engineered to meet the demands of a broad range of tooling and tool-making applications. Both PBLT Tooling Board (up to 200° F) and PBHT Tooling Board (up to 300° F) possess excellent machining characteristics and dimensional stability for tool-making. It is ideal for soft tooling and rapid prototyping because it can be more rapidly machined and it is more economical than alloy or epoxy-based alternatives.

Interested in trying your own test on Precision Board?  You can get a free sample or call our technical team with your questions at 800-845-0745.

Trotec Laser Engraving of Precision Board HDU PBLT-15

 

Are you wondering if Precision Board HDU can be cut with a laser-engraver?  Absolutely!  Our friends at Trotec Laser cut a variety of shapes out of a piece of PBLT-15 Precision Board, including our logo and a highly-detailed relief and sent us setting information.  You can see photos and watch videos below of Precision Board HDU being engraved and cut by a laser machine.

trotec laser

Trotec Laser used their Speedy 400 machine to engrave and cut the 15 lb. Precision Board.  The machine has maximum processing speeds of 140 inch/sec and includes the system’s patented low-maintenance design which encloses fragile system critical components in a rugged housing, protecting them from dirt and dust, which significantly minimizes maintenance requirements, down time and overall ownership costs.  The system settings they used to cut the various shapes, logos and reliefs out of Precision Board HDU are as follows.

Engraving Settings:

Power: 100%
Speed: 30%
PPI: 500
Air Assist: On

Cutting Settings:

Power: 100%
Speed: 0.5%
Hertz: 1000
Air Assist: On
Z Offset: -0.08

Some benefits of laser cutters:

  • Lasers are extremely versatile, able to process a wide variety of materials and need no additional setup, i.e. chemical additives or post processing.
  • Ease of use, with software packages compatible with most graphics programs.
  • Low energy consumption and speedier processing times.
  • Minimal equipment maintenance with low wear and tear due to no-contact process.
  • Extreme precision and detail.
  • Reduced waste and by-product because output is vapors which can be exhausted or ventilated with an air-filtration system.
  • Consistent quality level due to ability to save parameters of specific jobs and materials in database.
  • No material finishing required.

Source: “Advantages of lasers versus other methods of cutting, marking and engraving signs” – Trotec Laser, Inc.

Trotec used “Relief Mode” to engrave the above relief into Precision Board and achieve such fine detail.  Applications Specialist Josh Stephens says, “That is a function in our JobControl software that processes grayscale images at varying power levels, achieving a three-dimensional effect.” He added, “during this process, the laser power is proportionally controlled depending on the grayscale value of the graphic, meaning that white pixels are processed without power, light areas have low power, darker areas will have more power, and black will have maximum power.”

JobControl is a Trotec exclusive software that comes included with their Speedy and SP series systems.  Watch the video below to see “Relief Mode” in action on Precision Board HDU.

You may be concerned with the toxicity of using lasers on Precision Board, but you shouldn’t be.

According to a study conducted by Universal Laser Systems on the effluent created from laser cutting several different densities of Precision Board indicated that, “the effluent stream is primarily composed of carbon monoxide, acetone, propene, and acetonitrile. The concentration of the detected compounds did not exceed their respective OSHA PEL at any level of filtration during this study.”

Permissible Exposure Limits (PEL) are federal regulations that dictate safe chemical exposure levels.

Head over to precisionboard.com to request free samples and try it for yourself!

Trotec Laser is a leading international provider of advanced, high-speed laser equipment for cutting, engraving and industrial marking, and a wide selection of engraving supplies. Trotec was originally founded in Wels, Austria in 1997 and established in the United States in Mississippi in 2002. Now headquartered in Plymouth, Michigan, the U.S. business has grown to 10 times its original size.

SEE ALSO: Laser Engraving and Precision Board HDU

Sign Builder Illustrated: Mixed Media HDU Signage

If you’re curious about using Precision Board high-density urethane for signage, the November issue of Sign Builder Illustrated has a great article featuring Kevin Pirok of Pirok Design in Illinois.  HDU’s very low expansion and contraction rate has allowed Pirok to use the substrate with different materials in custom pieces for clients—mixed media, if you will.  He finds it easy to carve, easy on his machines, and easy to come up with big ideas for a small shop.  Check out these excerpts and then click on the link at the end to read the full article online.

pirok design

High-density urethane (HDU) has proven a popular substrate for shops looking to create lighter weight custom signage that mimics the appearance and textures of heavier materials.

“If you’re trying to [replicate] a stone, brick, or wood effect, HDU can simulate this very well,” says sign maker Kevin Pirok. “Most of the time, you can’t even tell the difference in which actual material was used in a finished piece.”

Pirok has utilized HDU for projects since opening his doors, as this easy-to-handle substrate allows him the flexibility and ability to custom-cut shapes and letters himself in his shop. In fact, he has been using Precision Board HDU from Coastal Enterprises ever since the product was released nearly twenty years ago.

Pirok mentions an upcoming project where his customer has requested a carved HDU monarch butterfly as part of their logo. “I’m cutting it by hand,” he says. “I’m going to layer up Precision Board to achieve the required thickness.

“From that point, I’ll go in and start carving. Working with this material is like going through butter with a hot knife at times.”

He points out that carving HDU is much easier than carving wood in a variety of ways. “When carving wood, you have to consider the grain direction,” he says, “but with HDU, there is no grain or knots.”

We profiled Kevin Pirok on our blog earlier this year and talked to him about using Precision Board to create dimensional wayfinding signs for Blackberry Farm’s tourist attractions.  You can read that blog here.  If you want to read the rest of the Sign Builder Illustrated feature piece, you can find that article here.

If you’re in the market for some amazing sign designs or other company branding, you can call Kevin at (630) 365-9870 or visit the Pirok Design website to see an extensive photo portfolio of their work. We think he’s a great guy and does beautiful work, but call to verify for yourself!

Want to use Precision Board HDU for your next project?  You can request free samplesSign up for our monthly Blog Roundup while you’re there.  It’s packed with tips and tricks to get the most out of your HDU project.  You can also give us a call at 800-845-0745.  We’d love to hear from you!