Vacuum Forming In the Movies: Flix Fx

Marc Pollack of Flix FX, Inc in North Hollywood, CA has been producing special effects/props for use in TV, commercials, movies, events and the music industry for the past 21 years. They’ve branched out to include a new patent pending process that will expand the horizon of what can be done with vacuum forming by being able to digitally pre-print a registered graphic image on the plastic prior to the forming process.  It creates a finished product that is useable in POP, theatrical, retail advertising and many other applications.

Step 1: Digital File

Step 2: Digital 3D Sculpting

Step 3: Routed Precision Board Plus

 

 

 

 

Step 4: The Final Result

 

 

 

 

 

 

 

Flix FX also known as 3D Vacuprint, has been using Precision Board Plus PBLT-10 on the majority of their 3D relief carvings. They start with a 2D image and create a 3D file through specialty software. The 3D file is converted to a file that is readable by the CNC router, which cuts the 3D profile in PBLT-10. At this time, a 2D image is printed on plastic, using proprietary software to compensate for distortion on the finished form. The final step is to register the form under the plastic and vacuum form it.


Marc says, “We can get 50-150 pulls from the PBLT-10 and when we need more than that, we’ll switch to a higher density or make a fiberglass mold.  Just like anything else it has its purpose and where it fits.  Precision Board Plus is our material of choice, and is a vital step in the creation of our product.”


For one of their recent projects, the Flix FX team created Toyota Drones for a television commercial.  The forms for the drones were machined from PBLT-10, the carbon fiber fin was processed by 3D Vacuprint.  The form (drone) was then vacuum-formed and used in the commercial that was played for NASCAR audiences.

Watch the video clip. If you would like more information, give Marc a call at (818) 765-3549. Take a look at their web sites to see the diverse projects for both Flix FX and 3DVacuprints.

HDU Vs. Wood Signs

Why are HDU signs more popular than wood signs? Wooden signs often fall victim to moisture intrusion, which will then cause the sign to swell and the paint to crack. A wooden sign requires much more maintenance, commonly requiring yearly repainting to keep it looking fresh. HDU is also much more readily available, and being a certified green material, it is also an eco-friendly choice.

HDU signs last so much longer because high density urethane is made up of millions of tiny cells, which are not interconnected, which means moisture can never get in. This is the reason why Coastal Enterprises offers a “Life of the Sign” warranty, against your sign warping, cracking rotting or splitting. When your HDU sign is painted, it will look just like wood and last much longer.

We often hear from people that they’ll never forget the first time they tried hand-carving with HDU, and how it was immediately clear that it was the perfect hand carving material. The consistency and various densities allow you to truly fine tune your hand-carved project specifically to your individual needs.

As mentioned in our FAQ section, any woodworking tool can cut Precision Board Plus. Rasps, dremels, and craft drills are all great tools to use for shaping. Standard wood carving tools work great, and in cases where extreme detail is desired, dental tools also work well. You can find a nice selection of carving tools here.

An interesting article in Sign Builder Illustrated, written by Mark Roberts, details the process he used to incorporate some hand carved Precision Board Plus HDU into an aluminum sign for a park. Check out the full article on page 18 here, and learn what his “secret weapons” are for hand-carving Precision Board Plus HDU!

If you have any questions, we offer free technical support and samples and can be reached at: (800) 845-0745.

 


 

Sierra Technical Services: Engineering and Composite Tooling Services For Your Project

Sierra Technical Services, or STS, located in the heart of the Antelope Valley can give you the composite tooling and engineering help you need. With over 30 years of experience, specializing in the manufacturing of composite tooling and structures, and aerospace engineering services, STS will help you get to your desired solution quickly and economically.

Their composite manufacturing services include mold fabrication, Nomex honeycomb core, and fiberglass and graphite composites. Roger Hayes, at STS, uses Precision Board Plus for his composite mold fabrication because of its ease of use, large sheets and blocks readily available, and the technical assistance he gets from Coastal Enterprises. “Precision Board Plus, in either the PBLT or PBHT, is delivered in large standard sizes, up to 5’ x 10’, ready to machine on our CMS Aeres 5-Axis, High-Speed Machining Center. This is a great advantage that saves us time and money compared to bonding multiple boards from another manufacturer.”

STS’s CMS Aeres 5-Axis, High-Speed Machining Center

 

Their group of hand-selected engineering talent, who specialize in everything from aerodynamics, mechanical design, tooling, and more, will provide you with engineering services at their facility or yours. Combine the experienced group of engineers with their quick-paced manufacturing services, made possible with the help of Coastal Enterprises, Sierra Technical Services will help you get your engineering and tooling needs done as efficiently as possible.

Visit Sierra Technical Services’ website at sierratechnicalservices.com, or call them at 661-824-3992, to see additional work and how they can help you.

Looking For An Easy To Use Crack Filling & Repair Material?

FSC-360 WB is a water-based crack filling and repair material specifically formulated for use on Precision Board Plus high density urethane (HDU). It can also be used on wood and metal and it adheres well to most plastics. If you are looking for an easy to sand, quick-drying repair filler for use on multiple materials, then FSC-360 WB is the perfect choice.

FSC-360 WB can be used to repair scrapes, holes and most types of damage. In addition, it is compatible with all types of finish primers and paints.

Check out our step-by-step video to see FSC-360 WB in action!

Looking for a FAST-CURING adhesive?

Are you in the market for a fast-curing adhesive to use on high-density urethane, wood, metal or other materials? Coastal Enterprises manufactures PB Fast Set ,an adhesive made for all types of materials. Being remarkably easy to cut, carve and sand, as well as being waterproof and fully cured in 30 minutes, PB Fast Set is an excellent choice whether you’re bonding Precision Board Plus or other substrates.

Check out out brand new step-by-step video if you are interested in learning proper laminating techniques and decreasing labor time:

Call us at: (800) 845-0745 or email us at: hdu@precisionboard.com for your FREE sample of PB Fast Set!