One of the world's foremost and recognised model makers recently commissioned Penta to supply twice life size figures utilising our latest 5 axis CAD CAM technologies.
Brief :
To produce composite models from supplied scanned data, within an extremely tight lead time.
Concerns and Considerations :
Traditional manufacturing processes and materials had been refined to a point where further economies of time were difficult to achieve.
Quality and delivery were paramount.
Our process :
Once our project team had captured the clients requirements, rapid development of the scanned data - to produce a series of individual model components for ease of manufacture - was completed.
Sample materials were sourced and selected from our extensive supplier base.
Models were then cut on our high speed CNC machines.
Finally the individual models were hand finished.
Assembled and Inspected.
The result :
Our customer was delighted with the quality of the delivered models but also, just as importantly, thrilled with the significant reduction in production time.
Additional advantages :
Other advantages to the manufacturing process, due to the improved accuracy, finish and material characteristics became apparent to the customer following delivery of the models.
Project :
Conceived by the renowned pop artist Gerald Laing sketches of rugby players were brought to life by creating a magnificent 36 foot bronze statue of 5 twice life size players in a line out. This iconic statue now takes pride of place on the plaza outside the famous Twickenham Stadium the home of English rugby.
Gerald sculpted 1:0.75 scale clay models from his original sketches and these models were then scanned by scanning experts 3D Scantech to produce CAD models. Our brief was to then produce twice life size patterns from this scanned data to an extremely tight lead time and delivery date – the unveiling of the Statue by Her Majesty the Queen – the pressure was on!!!
Initially due to the huge size of the statue we had to establish split lines for each individual player which would enable the foundry to handle and produce the bronze castings. Working closely with our customer and one of our material suppliers, John Burn and Company a low density board was selected to give the required combination of lightness, surface finish and edge detail. Due to the complexity of the finished statue our large 5 axis CNC machine was selected to cut the foam patterns. Where machinery and cutters could not reach our highly skilled pattern and model makers used their traditional skills to carve hand finish and fit each individual intricate pattern to ensure each one was completed to the same exacting standard our customer was demanding. The patterns would need to match to each other to extremely tight tolerances not only geometrically but also visually any error being magnified, an extremely tall order if you can mind the pun considering the final statue would be over 36 feet tall and accurate to + or - 1mm when set on its final base, any in-accuracies would be magnified.
The unveiling of the statue was a huge success not only marking an historic day for Twickenham but also for Penta celebrating 25 years in business. The magnificent statue now stands majestically outside Twickenham for all to see, a testament to the artistry and skill of all those involved.
We are extremely proud to have been associated with this wonderful project but more importantly of our highly skilled and dedicated team past and present who have for 25 years provided our colleagues and customers with unrivalled products and services.
