Tech Brief 01-05-018

Reverse Engineering Phoenix Award

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Problem:

When the DOD wanted to make scaled duplicates of the Phoenix Award for Maintenance Excellence, they called NeoMetrix.

Traditional Method:

Contracting an artist to recreate a reduced scale work of art can be time consuming and expensive. Silicone molding of the original will work for a full scale model, but the scale cannot be reduced.

NeoMetrix Solution:

  • Original piece is scanned using the Faro ScanArm.
  • Scan Data is registered, merged, and aligned in Rapidform XOR.
  • Final model is scaled down to the desired size.
  • Prototype part is printed on the Objet Alaris 3D Printer with a layer thickness of 28 um.
  • RTV silicone mold created using Objet part as pattern.
  • Multiple Urethane parts can be produced from a single mold.

NeoMetrix Advantage:

  • Rapidly capture part geometry through laser scanning.
  • Accurate tooling created overnight ready for multiple runs with customer choice of material.

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Figure 1 – Phoenix statue

Figure 2 – Phoenix objet part

Figure 3 – RTV silicone mold and urethane casting