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oxenham1

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Here's a job we just wrapped up. It's a 3 foot tall cartoon bear for Teddy Mountain build a bear. This is the vacuum mold machined entirely from MDF. 4 layers of 3" mdf, machined in slices. I think there will be a whole pile of different characters to do, and they'll all use the same back mold (not seen) It was a bit of a design challenge, as it had to be able to fit in a 24X24X36" shipping carton, and fit the mechanics that would go inside. These will be portable machines, with a collapsible suitcase style handle, and casters for rolling. We also had to think ahead a little, as the backs of the machines will have to fit all the different fronts that haven't been made yet.
The 3-d model was created in Hexagon, then sent to Aspire 4.0 for adding the draft angles for forming, as well as the flange lips, slicing and toolpathing. I also punched in the recesses for the stickers that will get added in Aspire. This should prevent them from getting caught and peeled off!


[cartoon-bear-aspire-3d-model]
[cartoon-bear-3d-model]

8)
JWO


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Jamie Oxenham http://www.oxenhamdesign.com
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Dan Sawatzky

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Very cool!

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Leo Voisine

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Cool Stuff Jamie
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Imagine the possibilities
Steve Luck

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Will you post what it looks like finished? Very cool Jamie.
oxenham1

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Thanks guys! I stopped by the shop who's job this is to see the pulls, as there was a bit of concern of some of the depths before pulling.



[image]
The pulls came out great! 3/16" abs styrene and very strong! These should last for a long time. In fact, they didn't even need to blow air into the mold, the parts just lifted off the mdf molds. Apparently they had to unevenly heat the plastic to avoid any webbing on the deep draw sections.

[vacuum-formed-3d-bear]
I also drew up the graphics for the stickers based on the company's mascot logo, and did a quick test fit. Almost perfect, they do need a little tweaking though. The center recess in his belly gets cut out to show the tube that will have the fluff blowing around inside. There will also be a stainless tube sticking out of his right paw that will be used to stuff the bear skins.
[20131108_121651]
Here's the back section. The 2 horizontal recesses are where the suitcase style retractable handle bolts to on the inside. The bottom right of the part has the angled plates for the castors, and the square recess in the lower middle section is where the footswitch will lock into when it's being traveled around. I solved the "same back with different fronts" problem by using interchangeable 3/4" plates that mount to the face of the back mold. This plate is basically a profile of the front of the machine, with a plastic thickness offset inwards. I think it's supposed to debut at the IAAPA show in Florida on the 18th. I wish I was going!
Thanks for reading guys!!
8)
JWO

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Jamie Oxenham http://www.oxenhamdesign.com
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Dan Sawatzky

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I can only imagine the amount of thought it takes to make everything line up and work as it should. GREAT job!

-grampa dan

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Dan Sawatzky
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oxenham1

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Thanks Dan! It gets a little overwhelming at times, then one thing changes, and it get amplified over the whole job, geometry changes, blah blah blah [smile]
Here is the final guy though:
[20131112_154829]

[20131112_154809]
8)
JWO

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Jamie Oxenham http://www.oxenhamdesign.com
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MarekHeil

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Make a couple so you can use them as suitcases when you travel. No problem finding those in baggage claim!
-Marek
mikeacg

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Very cool! I used to have a little 12x24" vacuum former years ago but didn't have a CNC to make my patterns so most of what I did was pretty lame... May have to revisit that whole thing again, now that I see this! Thanks for sharing, Jamie!

Mike

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oxenham1

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Quote:
Originally Posted by MarekHeil
Make a couple so you can use them as suitcases when you travel. No problem finding those in baggage claim!
-Marek

Actually, I think thats where they got the idea from, as one of the design references was a little plastic penguin suitcase!

8)
JWO

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Jamie Oxenham http://www.oxenhamdesign.com
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http://forums.oxenhamdesign.com/post/3d-summer-modelling-challenge-6946988?pid=1283204501#post1283204501

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