Using Real Steel & Faux Metal to Fabricate Sawatzky’s Theme Park Train

Coastal Enterprises, manufacturers of Precision Board HDU, is proud to announce a series of guest blogs written by Dan Sawatzky of Imagination Corporation, posted to the Precision Board Blog each month.

This month Dan Sawatzky tells us how he created a cartoonish-looking steam-powered train out of real steel and 30lb Precision Board HDU coated to look like rusted metal for a theme park.  Dan’s work is so good that you can’t tell what’s actually metal and what is faux steel.  Read on to see why Sawatzky used a combination of metal & HDU made to look like metal for his train and how he pulled it all off.

train

In Dan Sawatzky’s own words…

I thought I’d do an article on a train I built six years ago. It was done for a mini golf park which we designed. Now, the golf park has been closed to make way for a housing development. The train and all the other features we built for the golf park have been carefully removed and will be reused in another project which is soon to be built. I had a chance to look over the features this past summer. They are holding up great – a testament to how well Precision Board holds up!

The old steam-powered locomotives have long been a personal favourite. A number of years ago, just after we got our MultiCam, I got the chance to build a slightly cartoonized version. It was challenging, but a whole lot of fun!

train

While a fair amount of the train engine would be built of welded steel, Shay locomotives have a lot of intricate details which I knew would route perfectly from 30 lb Precision Board. The router would speed things up a whole bunch and once painted with a rusting paint would be impossible to tell from the real thing.

I first did a scale concept drawing. This was approved by the customer. I would scale up the concept to create a locomotive that was about eight feet long and six feet tall. I imported the concept sketch into EnRoute to create the vector drawings I would need for the routing files.  Many of the pieces needed to be layered to get the heavy duty ‘castings’ I needed. The bulk of the bigger pieces were routed from 2” thick 30 lb Precision Board. The wheels were routed from 3” thick board. The balance of the smaller pieces were routed from 1” thick 30 lb board. Since this was to be a static display even the train rails were routed from Precision Board. There were more than a hundred pieces in all.

 

I routed the wheels first so I could begin building the frame of the train while the rest were running. I mocked up the pieces first to make sure it looked right, then when I was happy, I welded things into place securely.

The boiler of the train was made with scrap sections of pipe. The bulk of the upper portion of the train was made of steel for strength. The routed bits were fastened to this structure. Most of the train was assembled in place on the train to facilitate finishing in a logical order.

I painted the Precision Board with a reactive iron paint and with a little spritz of the activator (a mild acid) the rust quickly formed on the Precision Board pieces as well as the raw steel components I used. It was impossible to tell which was real steel and which was not.

Once each assembly was finished I moved on to the next, working my way up the train.

While I was working on the train we learned the sad news that our niece was still born. I decided to name the little locomotive in her honour. A special name plate was created and mounted on the back of the cab.

train

I had been collecting old rusty chains for quite some time and this was the perfect place to use them. The jewelry was the perfect touch to make the train look real! The smokestack was the last piece added. We had it custom-made in a local machine shop as they had the necessary equipment.

The train was numbered with the numeral two as I often do. The reason is that I am the second child in my family. This is my way of signing my work.

Once complete the train was loaded onto our little flat deck trailer and hauled to our customer’s work site. He had a giant excavator waiting and in a few minutes the train was sitting high on the trestle he had built for the purpose. I built a log car in the same fashion which was lifted up onto the trestle and placed behind the locomotive.

 

The train acted as a feature and giant sign for the golf park and served the project well for the last six years. Soon it will be re-erected in a new location to continue to delight guests for many years to come.

 

train

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.

Hogging out Precision Board at a depth of 2.25″ on 1st Pass with X-Edge

Jim Dawson with Synergy Sign wanted the ability to machine through 2″ thick Precision Board HDU in a single pass, but he didn’t have a router bit that could get the job done.  He reached out to X-Edge Tools to see if they could develop something for him.  They worked extensively with Jim to create a new ball nose router bit (XCT518) that was up to the task.  Dawson successfully tested it out on a sheet of PBLT-30 Precision Board HDU from Coastal Enterprises.

“Hard to believe, but the new bit hogged through the Precision Board at 500 inches per minute while maintaining a nice, clean edge,” Dawson stated.  “More importantly, I was able to rout the material at a depth of 2.25″ on the first pass,” he added. 

Not only is this new ball nose router bit available and on the market now, but we’ve got speeds and feeds info to help you use it to cut Precision Board HDU down to depths of 2″+ on your first pass.  You can also watch videos of the router bit in action to see and hear how it sounds hogging out HDU.

x-edge

“I contacted X-edge tools with a need for a longer tapered ball nose bit that would allow single pass machining in 2” high-density urethane material.  X-Edge obliged and worked with us to develop and prototype and bring that bit to market,” says Dawson.  He adds, “what we got in the end was an amazing piece that allows us to machine faster and more accurately thanks to X-Edge!”

Jim’s MultiCam CNC went down to a depth of 2.25 inches at 500 IPM and 16000 RPM on the first pass.  

Here’s more information about the new ball nose router bit (XCT518):

  • Brand: X-Edge
  • Diameter: 1/8″
  • Cut length: 2 1/2″
  • Overall length: 4″
  • Shank size: 1/2″
  • Taper:
  • Flutes: 3

Jim tested the new router bits from X-Edge by designing some test shapes using Enroute software and routing them out of a single sheet of Precision Board PBLT-30.

You can also watch other 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 is happy to help if you’ve got a technical question or are trying to figure out how to do something with Precision Board HDU.  Some of our best “how-to’s” have been the result of a customer contacting us with a problem they can’t quite solve.  We put our 30+ years of experience into coming up with a solution and then sharing it with everybody, so give us a call at 800-845-0745 or drop us an email.  We’d love to hear from you!

We offer 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.

 

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.

orange coast college

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.

[Best_Wordpress_Gallery id=”26″ gal_title=”OCC Students”]

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.

ucsd

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.

ucsd

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!