Model Builders Inc Blog

How a scale model helps envision and sell a gas processing plant.

Posted by Hal Chaffee on Mon, Mar 23, 2015 @ 11:41 AM

UOP had an investor meeting coming up and wanted to make a great impression showing the advantages of their prefabricated gas processing plant. UOP is the only manufacturer that makes a prefab one and it consists primarily of seven skids that can be trucked to the site. They also wanted to use this model for sales presentations and tradeshows. 

The UOP advantages are that the prefab gas processing plant can be made much more cost effectively in advance in a factory and there is little final assembly once the seven skids are shipped to the client's site. Furthermore quality control in the factory is much easier to manage than in the field.  UOP's competitors build  gas processing plants on site which takes far longer and their construction time is much more exposed to weather delays. 

UOP Gasification Plant Model

UOP prefabricated gas processing plant 1:48 scale model 25" long X 25" wide.

To have a real impact with investors and potential clients UOP wanted them to easily envision the prefabrication concept and how it went together. If they could pick up each of the seven skids to assemble or disassemble them by hand that would be very engaging and memorable. Furthermore clients would be able to see the key components in each skid. This is an effective way to relate to what each skid does and where it goes.

The model makes for quicker and easier comprehension of the entire plant than walking through the real one. Furthermore  the real prefabricated gas processing plant is too big to take to a tradeshow (or potential client) and most potential clients are not located near one of the installed prefabricated gas processing plants.

What were the keys to getting this model fabricated to meet UOP's short deadline and to be as effective as possible in generating sales? 

(1) Choose the right model maker.

Hire a professional model making firm with experience - in this case one that makes process models for heavy industry like oil, gas and nuclear models. This firm would know where to get the special materials necessary and have the expertise to help design and fabricate the model in about four weeks. For this model UOP hired Model Builders, Inc. in Chicago.

(2) Provide the information the model maker needs to build from right away.

UOP drawings were needed to build from and they were needed fast. Model Builders, Inc. suggested that only pdfs of some of the drawings were needed.  It would have taken more time and expense if the model maker had to get familar with the UOP CAD drawings since it takes a while (often several days) to get familiar with the many CAD assemblies and parts drawings.

The UOP Director of Corporate Communications recognized that the model maker needed the pdfs right away and put the key UOP engineer in Oklahoma in touch with the model maker. That same day the engineer was able to send out all the needed dimensioned drawings as pdfs.

(3) Choose the scale.

 The 1:48 scale was the right one for an engaging hands on demonstration and for transport in a personal vehicle if necessary. Furthermore a scaled flatbed truck was put on the model to help the viewer get a clearer idea of how big the skids were by comparison.

(4) Determine the level of detail.

One of the things about models is that viewers are often attracted to them when they are highly detailed. The details draw them in. With this model even the UOP designer was impressed with the detail accuracy. This is particularly helpful to the sales effort when UOP can discuss with potential buyers what each skid does and the component parts that do that.

Gas processing plant model

(5) Engage the viewer in creative ways.

UOP had Model Builders, Inc. make the seven skids as loose units that can be assembled and disassembled by hand on a simple base with a plan view of the site on top. That meant each model skid could be picked up by hand and assembled or disassembled in the appropriate location on a scaled drawing. The drawing was bonded to the top of the 1" thick 25" X 25" base board.

Prefab Gasification Plant model

The stairway next to the right hand and the crosswalk next to the left finger are each connected with magnets for quick and easy assembly.

 

(6) Use durable materials.

ABS plastic is a very durable material and is the primary material used in this model. Futhermore the bonding liquid chemically welds the parts together.

In contrast acrylic is brittle and sometimes cracks or breaks. Vibrations during shipping and handling, below-zero temperatures and other adverse conditions could cause breakage or the acrylic glue joints could come apart.

(7) Make the model easy to pack and unpack.

The cutouts in the thick foam make packing and protecting the parts from damage simple.

Plant 

UOP gas processing plant model case.
The flat base with plan view is below the parts seen here. The truck is in the silver box.

How effective was the model at the investor's meeting? It was so effective UOP decided to order a second one to keep at the home office for potential customer presentations.

Model Builders, Inc. is known for helping manufacturers, industrial designers, institutions and individuals go from idea to reality. Take the next step by contacting us at Model Builders, Inc., 773-586-6500 or info@modelbuilders.net .

 

 

Tags: industrial scale models, site model, plant layout model, architectural model, model, product model, engineering model, product models, industrial scale model, tradeshow product models, trade show product models, process model, plant layout models, scale model

Iterative prototypes and models are often key to a successful product

Posted by Hal Chaffee on Thu, May 01, 2014 @ 01:30 PM

Why do so many products fail in the marketplace? Maybe it is because the developer of the idea didn't do an adequate job of creating a series of prototypes and reviewing them with potential users.

1) The initial idea can be expressed as simply as on a napkin sketch to convey an initial product idea. At first an idea is normally just that with no physical prototype. The Smithsonian has a wonderful exhibit called "Doodles, Drafts and Designs"  that shows examples of this earliest stage of a new idea for a product (see http://www.sil.si.edu/exhibitions/doodles/ ).

Below is a sketch of a ashtray idea for the Scenicruiser bus by Raymond Loewy Associates.

ashtray sketch

 2) A simple prototype model can be an early representation of the final product. It could be as simple as taping or gluing a few pieces of material together. The potential users then have the chance to get a general picture of the product idea that is in development with requirements that are not entirely known and give their reactions to it. Our rule of thumb here is that less than 25% percent of the population can visualize things well in three dimensions unless it is built first in three dimensions.

3) Product development is a iterative process that can begin without a full specification of the final product. You can use a series of models to evolve the idea. To get started just part of the product can be developed and then reviewed by users to identify further requirements. Then repeating this process can continue until the final product appears to be ready for the marketplace. Learning occurs both with the development and with the use of these product prototypes in iterations. Use a series of models to evolve the idea.

4) In the words of David Kelley, the founder of industrial design firm IDEO, design is now a team sport. Model makers at IDEO are more frequently getting involved much earlier in the development of new products to help create the idea before it is physically made. The industrial designer doesn't dictate the design or necessarily be in charge of it.  Instead a team of people with diverse backgrounds (human interaction, user interface, product design, engineering, manufacturing, model making and more) works together to collaboratively and iteratively build on each others ideas. Make sure you have a model maker on your team because your product ideas are far less likely to be a success if you don't.

5) MIT Professor Eric von Hippel, the author of the books "Democratizing Innovation"  and "The Sources of Innovation", observed that users are often the ones who develop a product when they have a need for a new or better product and a place where they would use it. They are ahead of others in a important market.

The Sources of Innovation resized 600

"von Hippel also proposed and tested some implications of replacing a manufacturer-as-innovator assumption with a view of the innovation process as predictably distributed across users, manufacturers, and suppliers. Innovation, he argues, will take place where there is greatest economic benefit to the innovator." Here is a video on lead users studies that 3M did to find lead users to work with to create some of their new products. See: http://www.youtube.com/watch?v=tNKrX1QxN6U&list=PLD4C0E9AEDF085119 .

6) It is hard to fail if you show prototypes to those who would use the final product and get their feedback. Potential users get the opportunity to test the functionality of the prototype and give feedback to help improve the product.

For additional information you may want to review our blogs including this one "How successful product development was done with a model shop's help" at http://modelbuilders.net/blog/bid/192523/How-successful-product-development-was-done-with-a-model-shop-s-help .

Model Builders, Inc. is known for helping industrial designers, manufacturers, institutions and individuals go from idea to reality. Take the next step by contacting us at Model Builders, Inc., 773-586-6500 or info@modelbuilders.net .

 


Tags: product model, engineering model, prototype, industrial designer, model builders, model maker, prototypes, model makers, prototype models, industrial design, product development, product models, model builder, industrial scale model, industrial designers, prototype model

How successful product development was done with a model shop's help.

Posted by Hal Chaffee on Sat, Jan 11, 2014 @ 11:32 PM

Frequently a company or individual needs more expertise than they have  when working on the development of a new product especially in the creation of physical prototypes. The design, material selection, tool expertise and more may require the knowledge and skills of expert model makers to increase the odds of product success.

Let's take a look at how the Aluminum Extrusions, Inc. in Charlotte, Michigan got help from Model Builders, Inc. that was crucial to the development of their new wall hung Executive or Conference size board product sold by OMNI Products, Inc. That Visual Idea Center product, last known as the OMNIVIC II, sold well for over 30 years.

 OMNIVIC II Executive Conference Board Closed

Aluminum Extrusions, Inc. was looking to sell more aluminum extrusions and thought that developing a new conference board product that used aluminum extrusions in its construction might be a good idea to expand one of their office furniture conference board product lines from just heavy wood construction with piano hinges to a much lighter product that was primarily aluminum construction.

Using in house personnel Aluminum Extrusions, Inc. developed the product as far as they could. Then their industrial designer, Bob Vogele, found and worked with Bill Chaffee of Model Builders, Inc. to further develop the Visual Idea Center product idea.

Conference board OMNI VIC II


Bob and Bill came up with the final design and Model Builders, Inc. fabricated the prototype for the aluminum framed VIC product which only weighed about 100 lbs. whereas the current all wood framed Visual Idea Center weighed over 150 lbs. The new aluminum framed model could also have a laminate material in a variety of finishes applied to the front of the two light weight core doors as shown in the first picture above. Furthermore Model Builders, Inc. was responsible for sourcing and inspecting the materials for the first 100 units.

One of the amazing features of these boards is that Bob Vogele and Bill Chaffee developed a continuous patented hinge by changing the shape of the two vertical extrusions where the door panel meets the wall mounted panel. Then a custom single gray plastic extrusion could connects the front panel to the wall panel .This gave the conference board a very clean modern look and eliminated the need for the piano hinge which made assembly faster since the hinge screws weren't needed. Furthermore the door panel connection to the wall mounted panel easily passed the weight stress test.

Visual Idea Center hinge

DSC07312 resized 600Patented hinge with two aluminum extrusions and a plastic extrusion in the middle.

Other functions and design details were incorporated that also made the VIC II as widely popular as it was.

Conference board features

Hiring a model shop to work with you on product development should add a new dimension to the discussions and increase the odds of creating a successful product. Don't bring a model shop in for an appearance model at the end. Get the model shop involved with the product development at the start. Their expertise will greatly improve the final product.

Model Builders, Inc. is known for helping industrial designers, manufacturers and others go from idea to reality. Take the next step by contacting us at Model Builders, Inc., 773-586-6500 or info@modelbuilders.net .

Tags: product model, engineering model, prototype, training aids, industrial designer, prototype models, training aid, industrial design, product development, prototype model

7 things a model maker learned at the 2013 IDSA Conference

Posted by Hal Chaffee on Fri, Sep 06, 2013 @ 01:06 PM

The 2013 Industrial Designer Society of America (IDSA) International Conference was in Chicago during August and there was a lot to learn - here are 7 takeaways. 

(1) Persistence can be an inventor's friend, greatly improving the end product along the way. Dean Kamen described his 10-plus years trying to get his Slingshot water purifier to people around the world who don't have safe water. The hope is to eliminate millions of deaths from water borne diseases.

One major obstacle was worldwide distribution, which Kamen recently solved working with Coke whose international distribution system is one of the best in the world.

Another major obstacle was the economics of Kamen's water purifier and power source. His recent thinking is a 8' X 8' X 20' box could ship more services along with the Slingshot to improve the cost benefit ratio. So the plan now is that one shipment includes an energy source, the Slingshot water purifier, a satellite based communications system and refrigeration for medicines. This would be available to a whole village in a remote location. Looks to me like Dean Kamen may solve more than one major world problem as a by-product of trying to solve one. The implementation of this idea could improve health, education, and communication for billions of people.

(2) Expect a proliferation of entrepreneurship.   Prototypes are easier to make with 3D printing, money for product development and production is easier to raise, and products are easier to sell due to the internet and 3d printing. Here is one example that was on display.

Non spillable coffee cup

A young girl, Lilly Born, developed the Kangaroo Cup with the help of her father so that her grandfather who had Parkinson's disease wouldn't knock over his coffee or soup cup.  Prototype 1 was a rough handmade prototype. Prototype 2 was a 3D printed prototype (shown on the left in the above picture).  Then Lilly and her father both went to a ceramic factory in China to get a quote on the final Kangaroo Cup that they are now selling (the cup on the right in the picture). On Thursday Zach Kaplan of Inventables included a video on this project (see https://www.youtube.com/watch?v=HzNz25Kc5FQ ) in his presentation titled "Designers as Manufacturers: The Third Industrial Revolution."

(3) Expect to see more artistic-entrepreneurial products, too - ones that you often have a hard time getting funded - especially those that need anywhere from only a few thousand dollars up to 1 million or more. MINIMAL (MNML) and Kickstarter are enabling entrepreuneurs to develop and market their new product ideas as well as fund them.

Book pages light

This product is a book with pages that light up when the book is opened. The book can be laid flat on a table for the maximum amount of light or set down with the lit pages vertical and the book cover open or closed to permit the amount of light desired. Actually this is light that works like a book.

For a more complete look at the many Kickstarter projects displayed at the August 22nd exhibit at MNML in Chicago during the IDSA Conference see this page  http://www.mnml.com/21277/1756315/our-work/kickstarter-all-stars-presented-by-mnml .

(4) The "unconference" concept was a full day at the conference because IDSA members are excited about connecting with each other on topics  that they are passionate about.  This is the first time the IDSA tried this idea at their International Conference. On Friday  groups of 20-40 people had discussions during a 45 minute session on one topic that they signed up for. Anyone could propose a topic in advance and if interested could lead that discussion. Eight sessions ran concurrently in the 45 minute periods for most of Friday and  participants could wander from one session to another to discover something of interest. No projectors.  Just topical discussions - basically whatever you want. Some examples are "How is the 'Maker Revolution' going to affect ID?", "Origami and how it helps design" and "Creating an ID culture within an alien corporate climate".

(5) An "unconference" option on Friday was a three hour session called "Blitz" to brainstorm tangible ideas that can have a meaningful social impact. Social activist John Bieldenberg hosted this "Blitz" to help designers create concepts for new products and services that help to prevent bullying.  As a result suicides, especially of children under 14, and school-shooting incidents can be reduced. The session partnered with the Hero in the Hallway organization that has helped Chicago schools with their "Spirit Desk" system reduce suicides and prevent bullying.

(6) The 3D printed car contest was launched and crashed. It was a big hit. As in the real world industrial designers had a chance to test their concepts against tough competition and in this case have fun too. Furthermore the entrants had to use 3D printed models. The three prize categories were for best flight, best crash (there was a slow motion camera directed at the crash site) and best looks. The winner in each category was awarded a 3D printer. Inventables, Models Plus and Options and Computer Aided Technology sponsored the printed car contest.

1376713593_01

Above is one of the top ten car contest entries (out of over 100 entries) called "Balloona" designed by Ms. Reut Kovetz of Fahrenheit Design. Below is a picture after the ramp launch of the crash. The clear connectors are barely visible and so thin they break easily on impact and send the balls rolling in multiple directions.

The wheels and the optional ball bearing were installed at the conference. The entries were 3D printed at the conference on one of two 3D printers. Pictures reprinted with the permission of Fahrenheit Design in Austin, Texas. 

1376713599_06

Intrigued? Check out these videos:

Here's a link to the blog post:
Video of the race:
Here are all the cars (10 were selected for the launch):

Coincidently one of the conference speakers, industrial designer Byron Block, on Thursday revealed the biggest safety blunders in vehicle design. Byron has fought for and influenced the adoption of safer designs that are feasible - in rollovers with weak roofs, truck underside decapitation tragedies and unsafe fuel tanks that led to fire deaths.

(7) The conference was an incredible chance to meet designers of all stripes and be exposed to all sorts of new ideas and products. Below is one example - the SPUN swivel chair that won't fall over as seen at the Steng Design Party at Orangeskin on Friday night. The SPUN chair just keeps rotating around whenever you move.

Justin Eddings in the SPUN chair

Here Justin Eddings, an Interaction & Industrial Designer as well as the Product User Experience Designer at Sprint, travels in circles at Orangeskin. There were six networking events just on Thursday night and four more on Friday including a boat tour sponsored by Designcraft! 

If you wanted to find out where the world of industrial design is headed the 2013 IDSA International Conference was the place to learn from companies like Inventables, MNML, Kickstarter, etc. Like the personal computer before it the personal fabricator is taking industrial design, prototyping and production into an extremely fast growing part of the economy. Now individuals can actually find the funding and tools to prototype and produce new products and services that are custom made to the client or produced in small quantities economically. 

If you wanted to see examples of people who are making a huge difference in solving social problems Dean Kamen's presentation on providing clean water and more around the world got a standing ovation.  At John Bielenberg's hosting of the unconference "Blitz" brainstorming you could participate in trying to come up with concepts for new products and services that might turn schools around and even reduce suicides and shootings. Industrial designers are continuing to expand their work into solving big social problems.  

So why does a model maker go to an industrial design conference? We are two sides of the same coin and success depends on close collaboration. Many good ideas die in the development stage because implementation requires special skills and tools. Converting an idea to reality is often difficult - the skills and tools of both the industrial designer and the model maker are often crucial to the creation of a successful product. It is important to the success of the model maker and the industrial designer to learn from each other.

Model Builders, Inc. is known for helping others go from idea to reality. Take the next step by contacting us at Model Builders, Inc., 773-586-6500 or info@modelbuilders.net .

 

 

 

 

Tags: product model, engineering model, prototype, industrial designer, model builders, model maker, prototypes, model makers, prototype models, industrial design, product development, product models, model builder, industrial designers, prototype model

To make a plant layout model what does the model maker need from you?

Posted by Hal Chaffee on Thu, Jul 18, 2013 @ 06:52 PM

To quote and build a plant layout model the model maker needs information from you. With your answers to the following eight questions you can get a quote and timetable for a plant layout model that best meets your requirements.

1) What do you need a model of?

Does the plant model reprsent one product production line, a number of product lines, a distribution center, a process like an oil refinery with multiple buildings, tanks, piping and other structures? Is it an interior model only or does it include the site outside the building?

Plant engineering studies often use a plant layout model to help analyze different equipment configurations and layouts. An existing or proposed facility may be limited in space and determined by an architectural structure. Equipment models, block or detailed, may be used to represent the different types of equipment. The model equipment depictions can be moved around in the facility until the best layout is determined. In office areas plant layout models help determine how to divide office space and show other floor space options.

Many companies use a physical plant layout model in the process of optimizing the entire plant design including electrical, water, hydraulic and HVAC before construction starts. This engineering model provides a three dimensional view of the current design which acts as a focal point for communication among all of the engineers and other personnel involved.  Normally the model pays for itself by reducing or eliminating misunderstandings, omissions and reducing drawing requirements. 

A plant layout model is particularly helpful where there is a lot of complex piping. The piping can be color coded with industry standard colors to make it quicker to understand. If there are errors in the piping drawings they are discovered when a physical model is made and that saves time and money when the real piping is installed.

Plant Layout Searle

Pharmaceutical multi-story interconnected plant layout planning model

Sometimes a plant layout model of a large site is used to explain a process like water treatment to customers or the public so they can more easily visualize all of the buildings and tanks as well as their interrelationship. 

 2) What is the purpose of the model?

 If the model maker knows the purpose of the model you may get suggestions that improve the model to better achieve the purpose. For instance arrows on the equipment or floor may help in clarifying the direction of travel in the production line.

-Production line with arrows

Conveyor direction of travel shown with arrows 

- Are you building a new production line and using the model to figure out an optimal equipment layout?

- Is the plant layout model for production training in a manufacturing plant?

- Is the model to give an overall view of a large production area to show potential customers?

- Is it a focal point for employee quality meetings?

- Is it a plant layout model for planning changes in the production line?

- Perhaps the model is to explain the best design features to your workers, managers or clients.

Let the model maker know the purpose and what is important to highlight on the model.

3) What is the scale?

You may or may not have figured out how big you want the model.  We find it quite helpful if the potential client has already printed out a plan view and some elevation views of the model in the scale they think they want it.  They may find some important details such as control panels, piping or handles are too small in the model scale they originally thought they wanted. We have noticed that a number of clients need to see the printed out views before they can be sure it is in the right scale for their use.

Common scales for plant layout models are 1:48, 1:100 and 1:200.  A lot of model structural parts, materials, architectural parts, vehicles, people, landscape detail, etc. is available in those scales. It often helps to have a scale person(s) or vehicle(s) in the model to make it easier to understand visually the model scale.

If there are railroad tracks in the model it is much less expensive if the model is in a standard railroad hobby scale.  1:87 scale is HO gauge which is the most popular railroad gauge, 1:160 is N gauge. and 1:220 is Z gauge. For larger scales track exists. 1:48 scale is O gauge and 1:24 scale is American gauge. Tracks in a few other large gauges exist. A lot of plant layout models are 1:100 scale which is close enough to HO gauge that HO gauge railroad tracks, railroad cars, vehicles, people and cars are often used in 1:100 scale models.

4) Do  you have drawings and if so in what format?

 Model cost estimates should be based on requirements that are well thought out before the fabrication of the model begins. To get a model quote it is helpful to have at a minimum pdfs or alternatively printouts in the desired model scale with plan and elevation views. A common CAD file format is .dwg or .dxf. but many other common CAD formats can be used. Photographs of the plant and equipment are also quite helpful in determining the quote.

If not available at the quote phase then before model fabrications begins the model maker needs any detailed drawings that may be available.  If you do not have a complete set of drawings it is helpful to provide a list of what is missing. The drawings should also be reviewed prior to giving them to the model maker to be sure that there are no earlier obsolete drawings included or obsolete file types like .CAL files.  We have seen projects where the quote had to be revised by up to 40 percent more because 400 out of about 1,000 drawings were obsolete earlier versions of the same drawing, were not needed to build the model or were missing.

5) Do you need explanatory labels, diagrams or lights?

A control board with labels on the side of the model could also light up specific machines, areas or builidngs in the model. Chase lights could be added to show the flow of a production process. See our earlier blog on a plant layout model with a control board and lights at http://modelbuilders.net/blog/bid/154286/This-waste-water-treatment-plant-layout-model-shows-how-it-works .

6) What type of base do you need? Do you need a clear plastic dust cover? Do you need a shipping crate or case?

Models larger than 4' wide X 8' long are often made on multiple tables that butt up and line up with adjacent tables on one or more sides. If the model  is 4' X 8' or less then often the base is about 4" high wood that frames all four sides. Removable legs or a credenza style base underneath (with or without doors) could be added under the wood framed model.

A clear plastic dust cover is not used very often on a base that is bigger than 4' wide X 8' long. Usually a clear plastic barrier would be put on the sides instead. Although clear acrylic does come in 5' X 10' sheets it tends to bow downward on the top of the dust cover in that size.

Some plant layout models could be 2' X 3' or smaller.  For smaller models a ATA style shipping case could be used if desired. Larger models may need to be shipped in a wood crate, customized packaging or a dedicated van or truck. It is usually best to have the model maker, who knows best where the model might need extra protection or support, produce the shipping container.

7) What is your budget?

The price of a plant  layout model depends on a variety of choices that are to a large measure determined by your budget. The scale of the model, the number of parts, the level of detail and many other factors determine the final price. You can save yourself and the model maker a lot of time by defining a price range or maximum at the start of your conversation. Then discuss which of the choices will reduce or raise the price. Block depicted equipment is less expensive than detailed equipment for example.

Mfg Plant  Block Depicted Equipment resized 600

Block depicted equipment in a manufacturing plant model

There are three major steps in making a plant layout model.  They are design, planning and fabrication. If you have thought through a lot of the design and planning as well as provide drawings, illustrations or pictures, etc. of what you want then the price will be lower than it would otherwise.  

8) Who will the model maker be working with on clarifying the marketing and technical details?

The model maker needs to talk with the person or persons who can provide the best and quickest answers to marketing and technical questions during the planning process. That cuts costs by improving the model maker's ability to prepare an accurate quote at the outset rather than dealing with additional work orders.  If you provide the essential information during the quote process the model maker does not have to add to the quote a figure to research the answers to vague or incomplete information.

The final model is often best if it is a collaborative effort between you and the model maker.  Model Builders, Inc. is known for creative, economical, realistic plant layout  models. Take the next step by contacting us at Model Builders, Inc., 773-586-6500 or info@modelbuilders.net .

 

 

Tags: industrial scale models, site model, plant layout model, architectural model, architectural models, engineering model, industrial scale model, process model, plant layout models, nuclear model

Construction equipment product models increase sales and cut costs

Posted by Hal Chaffee on Wed, May 15, 2013 @ 10:33 AM

There is nothing like demonstrating a real product at a tradeshow or event.  However if you are selling a large piece of construction equipment it may be too large or too expensive to do that. Consequently some construction equipment companies are using a custom model that will fit into an exhibit booth or is easily moved to a customer's office for a sales presentation.

Dragline model

Dragline model

Showing a construction equipment model at a work site such as on a railroad track can help the potential customer better relate to how the equipment is used.

Tamper

 Tamper ballast tamping machine model

Features of the equipment can be depicted. This 1:16 scale mining truck shows that the electrical equipment is concentrated in one place in a three door cabinet on the deck next to the driver's cab so that it is easy to access and fix. Using a control on the side of the model base the sales person can turn the front wheels to show that this truck behind the wheels has the most accessible engine for maintenance (there is a scale engine between the front wheels). Also the dump bed can also be raised and lowered (by turning a key) to attract attention at the tradeshow.

 

Mining truck model

         Haulpak 830E mining truck 1:16 scale model

In 1956 a 1/4 scale model of the Hough Payloader attracted crowds at tradeshows because it duplicaticated the hydraulic actions of the real front-end loader by using miniature cylinders and a new reversible pump unit. Automatic or manual operation was selected by the 4-pole transfer switch. In automatic operation limit switches control direction of current flow through armature and direction of motor control. In manual operation current flow was controlled by momentary pushbutton switches. This model was written up on two pages of the December 1956 edition of Applied Hydraulics magazine.

Hough Payloader

Hough Payloader 1/4 scale working hydraulic model

Use product models like those described above to help the product sell itself and grab the attention of potential customers at a trade show or on a sales call. Give yourself a competitive edge with a product model that tells your product’s story with impact and often without the use of words.

A construction equipment product model enables you to show your product in more places and at less cost than if you took the real product. Take the next step by contacting us at Model Builders, Inc., 773.586.6500 or info@modelbuilders.net .

 

 

Tags: construction equipment models, industrial scale models, railroad equipment model, product model, engineering model, model builders, model maker, model makers, product models, model builder, industrial scale model, tradeshow product models, trade show product models

Why do industrial designers use a model maker?

Posted by Hal Chaffee on Mon, Mar 04, 2013 @ 10:39 PM

Industrial designers hire a model shop or use an in-house model shop to build physical prototypes of new products and other ideas. Knowledge of prototyping, materials and manufacturing techniques enable the model maker to refine an idea from two dimensions into a physical model that turns that idea into a product.

Here are 8 reasons why industrial designers use model shops:

1) Reality. As stated on page 132 in the 1947 book "Design for Business" by J. Gordon Lippincott

  "Before any design goes into mass production, a full scale model should be made and, if at all feasible, an operating model.  The costs of tooling, merchandising and advertising are so great that any economies gained by skipping the model-making step are more than offset by the greater risk of producing an article that lacks consumer acceptance through failures in styling or function.

Renderings are particularly misleading and should serve only the function of stimulating new, fresh, creative thinking.  In other words renderings are only the expressions of the idea stage.  As soon as a proposed form for a new product has been selected, models should be produced - in full scale wherever possible or practical. Half and quarter-scale models are completely misleading because most people do not have the ability to appreciate changes in scale.  A molding on a quarter-scale model of a refrigerator may look perfectly satisfactory, but when the same design is enlarged to full scale, the molding will be completely out of proportion  - usually too large."

Raymond Loewy ashtray

Raymond Loewy stainless steel ashtray prototype for the 1954 Greyhound Scenicruiser bus

2) Capability. The industrial designer usually needs a model maker that has a shop with a variety of capabilities including machining, rapid prototyping, woodworking and finishing work such as sanding and painting. The space, machinery and model making talent needed to produce the industrial designer's prototypes and appearance models are simply too expensive to do at the industrial designer's location unless there is a constant volume of work to do.

The larger industrial design firms like IDEO and large companies like Steelcase tend to have an in-house model shop to create prototypes and appearance models. However for peak loads of work, special expertise or equipment, and a short run of parts they may use an independent model shop.

3) Expertise in materials. Professional model makers know from practical experience what materials may best meet the demands of the designer's intentions and the conditions a product will face. 

RAYOVAC ROUGHNECK flashlight

RAYOVAC ROUGHNECK flashlight - adjusts from Spot to Flood

4) Speed. Initial prototypes may be quicker if made in thin acrylic or styrene with vacuum forming.  Rapid prototyping is also used to create quick prototypes once the computer CAD work is done.  Machining plastic or metal is often the best way to create the final model since there usually can be much finer detail, more durable material and less finishing work. 

5) Product development. The initial design is tested with potential customers to see how well the product design works. Sometimes the product when held doesn't feel balanced. Many prototypes may have to be built and tested sequentially with changes before the product is ready to sell in the marketplace. Design is a collaborative process and model makers help the industrial designer perfect his craft.

prototype welding handle

Bernard welding handle final prototype

6) Appearance. A passion to do finishing work, the right grit of sandpaper, the right primer, the right shade of paint, a gloss, semi-gloss or flat finish often determine the success of a new product. The texture and finish must be the same as the final product. We hired one model maker because he could produce a flawless high gloss black finish on a wood base 10" high X 48" X 96". Sometimes industrial designers specify a specific model maker because of his or her superior finishing work.

7) Testing. Sometimes a design looks good on paper but doesn't work right when a prototype is built. The best model makers have the mechanical and electrial skills to help solve those problems.

8) Imagination. You never know when someone else's imagination, expertise, experience or knowledge may improve a product design. Model makers at in-house shop usually have a great knowledge of a particular product's history and techniques that were used to make that type of product.

Independent model shops often have a broad range of experience and may bring in new ideas from their diverse experiences.  At our independent model shop we sometimes find ourselves delving into a dusty two volume set of books titled "Ingenious Mechanisms For Designers and Inventors" that was first published in 1930 with chapter titles like "Intermittent Motion" to create special mechanical motions for a new product. Mechanisms in this book have already passed two important tests - (1) these are designs of mechanisms that will function properly and (2) they are simplified designs which normally are less costly to manufacture and more durable. This is just one example of the resources and experiences that model makers have. Last week we found a new nanotechnology based consumer product that removes and then prevents fingerprints on stainless steel.

If you have any questions or would like to discuss prototypes or other projects contact us at Model Builders, Inc. 773-586-6500 or info@modelbuilders.net .

 

 

 

 

Tags: construction equipment models, industrial scale models, product model, engineering model, prototype, industrial designer, model builders, model maker, prototypes, prototype models, industrial design, product development, product models, model builder, industrial scale model, industrial designers, prototype model

Museum model of ARAMCO oil rig 7' high is a Saudi highlight

Posted by Hal Chaffee on Fri, Jan 04, 2013 @ 05:44 PM

The Saudi Aramco Exhibit is in a high-tech museum near Saudi Aramco's headquarters in Dhahran and is dedicated to energy education. There are 8 permanent sections to find out about oil production, Saudi Aramco's history and Arab-Islamic history. Also included are many temporary exhibits. Important information is combined with fun for youngsters and the family as well. There is a 3-D film "Energy to the World", a variety of ingenious hands on displays and interactive computer games to involve, intrigue and educate visitors. Every year the exhibit attracts tens of thousands of school children and international visitors.

The Saudi Aramco Exhibit opened in 1987. It features three dimensional models such as the 7' high detailed oil rig model shown below. 

Oil was first discovered in Saudi Arabia in 1938 and ARAMCO later became the largest oil producer in the world. The exhibit dramatically tells the story of the petroleum industry and relates it to over 10 centuries of Islam (from the 7th to the 17th Century) technological advances and heritage. By the mid-ninth Century Arabic had become the international language of scientific thought.

Recently a National Geographic book "1001 Inventions - The Enduring Legacy of Muslim Civilization" (now in its Third Editon) and a traveling exhibition "1001 Inventions" (originally opening in the United Kingdom in 2006) has exposed millions of people to the Muslim technological advances and heritage. Currently the "1001 Inventions" exhibition is at the National Geographic Society in Washington, DC until February 3, 2013. We like to think "1001 Inventions" exhibit is based on the pioneering ARAMCO Exhibit that opened in 1987.

Oil Rig model 8' high

This 7' high oil rig model scale is 1/2"=1'-0" or 1:24. The model is in a scale that people can relate to and easily comprehend the entire oil rig as well as the details.

Oil Rig Model - Hook

Oil Rig Model - Traveling Block, Hook and Swivel

Visitors are inherently attracted to a highly detailed model such as this oil rig that looks realistic. The traveling block and hook above are part of the hoisting system. Below them is the swivel which is part of the equipment that rotates the drill. This is a Loffland Brothers Rotary Rig. 

The model is all brass construction that is silver soldered into a very strong welded bond that enables this fine level of model detail as well as durabilty. It will withstand exposure to extreme temperatures if it is ever displayed outdoors or transported in a vehicle that is not air conditioned. 

Oil Rig Model - Monkeyboard

Oil Rig Model - Monkeyboard

Fine detail like the monkeyboard platform is possible with the strong silver solder welding of the brass. The monkey board is used as the oil rig man’s work platform. The monkey board is located at a particular height in the derrick or mast. It is the same height as single, double or triple pipes.

Oil Rig Model Mud Return Line

Oil Rig Model - Crown Block

The crown block is a fixed set of pulleys (called sheaves) located at the top of the oil rig mast over which the drilling cable is threaded. The companion blocks to these pulleys are the traveling blocks. By using two sets of blocks a great mechanical advantage is gained. Consequently small steel drilling cable (3/4" to 1-1/2" diameter) can be used to hoist loads many times heavier than the cable could support as a single strand.

Colorful museum catalogs at the entrance (according to the Saudi Aramco World magaine November/December 1992 issue) go right to the point of the Exhibit that "it is meant to be a place for joyful learning...a carvansary for the curious" revealing secrets about the past, present and the juxtaposition of the two".

If you have any questions or would like to discuss oil rig models, site models, ship models, plant layout or process models, industrial models, nuclear training models, topographic models or other projects contact us at Model Builders, Inc. 773-586-6500 or info@modelbuilders.net .

Tags: construction equipment models, industrial scale models, product model, engineering model, product models, industrial scale model, museum model, process model

Nuclear training models improve safety

Posted by Hal Chaffee on Tue, Nov 06, 2012 @ 10:34 PM

Nuclear training models can be very effective in improving safety and reducing radiation exposure. These training models are often of a nuclear steam generator, a nuclear condensor, a nuclear reactor or even a nuclear plant site.  

The models are a focal point of planning and training discussions.  They provide a clear understanding of the entire process and the specific details of the parts and areas where workers will be doing upgrades, repairs and maintenance.

The Nuclear Regulatory Commission (NRC) rates each nuclear plant on radiation (rad) exposure. Training in advance of going into areas where an employee can be exposed to radiation normally shortens the amount of time they are there.  This helps employee safety and minimizes rad exposure for meeting NRC requirements.

Nuclear Steam Generator model

Nuclear Steam Generator training model 48" high (1:16 scale) with intuitive diagram

The nuclear steam generator shown above is a highly detailed training model used at Calvert Cliffs Nuclear Power Plant in Maryland. There are many features in this new model that improved training compared to the use of a prior model that had not yet been upgraded. Instead of numbers on the model and a list of numbers with the name of each part next to the model this new model uses the intuitive diagram just below the above pictured model to correlate (with black lines) the part name to the part in the model. It also uses red (hot) and blue (cold) arrows to show the process flow of the water and steam. Comprehension of how the steam generator works is quick using this cutaway model and its intuitive diagram.

 Cutaway View of Primary and Secondary Dryers

Primary and Secondary Steam Dryers

Above is a cutaway view of the primary (blue tubes) and above them the secondary dryers (in white) to show where the steam flows. The output from the steam generator is dry steam which goes out from the top of the steam generator and then into the turbine which generates electricity.

Manway Cover

The lower half of the steam generator model shows tube bundles (containing hot water) in lattice grid assemblies and one of the manways (with the bolts) in the middle. Every bolt on the manway covers and every latch on the hatch doors is shown on the model which is important as there is a specific sequence that should be used when opening each one.

For more information on this and other nuclear models please reference a 5 page interview titled "Bill Baines: On the use of steam generator modeling at Calvert Cliffs" in the April, 2003 issue of Nuclear News magazine published by the American Nuclear Society (ANS). Go to this link docs/2003-04-01-NuclearNews-SteamGeneratorModel-ModelBuildersInc.pdf .  

Calvert Cliffs also has a scale model of their reactor vessel and its internals.  Bill Baines, the program administrator for the Engineering training program, oversees the initial and continuing training of about 180 engineers and analysts at the plant.

In the U.S. nearly 20% of power comes from 104 reactors which were mostly built between 1967-1987. Upgrades to existing equipment such as to the two Calvert Cliffs steam generators are where scale models are used for planning meetings as well as for training. The models allow everyone to see how the old and the new steam generators differ and what the workers could expect to encounter.The models provide project personnel with a visual 3-D model that shows how components might interfere with each other during removal and installation.

The US Department of Energy and some nuclear plants are also using a site model for planning and reviewing security procedures on a regular basis. Communication is easier when everyone is looking at the entire area being discussed.

If you have any questions or would like to discuss nuclear training models, site models or other projects contact us at Model Builders, Inc. 773-586-6500 or info@modelbuilders.net .

Tags: industrial scale models, plant layout model, architectural model, architectural models, engineering model, training aids, training aid, industrial scale model, process model, plant layout models, nuclear model

How to create a trade show exhibit that sells

Posted by Hal Chaffee on Tue, Jun 19, 2012 @ 09:06 PM

To create a trade show exhibit that sells, focus on solving these three basic problems:

Problem 1: How do you get the attention of your highest potential buyers?

Answer: Use a concise headline in the most easily seen part of the exhibit - put it up high, make it big, light it up. Repeat the headline elsewhere in the exhibit. Use the company name nearby. 

Focus the headline on a specific product, or service and make a strong benefit promise. For example, Uni-tek's headline is "Broken Taps Removed Fast" in large, flood-lit lettering. Sharp focus like this attracts people who want what you have to offer.

You have five seconds to attract the attention of potential buyers and less than five minutes to develop interest. 

Problem 2: How do you develop detailed product interest?

millennium ball model

Photo: A 30" diameter model of the Millennium ball drops slowly a few times a day in synch with a video countdown at this 50' trade show booth for Philips light bulbs, drawing attention to the  key product benefits on the billboards.

Answer: Highlight the product. Use a sales message with the most important features and benefits. Show your product or service in action. Invite the potential client to participate in a product demonstration.

Remember the product is the star. Consider a cutaway of your product to highlight how it works.  Make a small product larger with a realistic larger-scale model as the center of attention in the booth, like the 5' high spark plug Bosch used. For a large product like a locomotive, aircraft, or mining truck, feature a smaller-scale model that fits in the trade show booth. Consider adding mechanical movement or chase lights to show the sequence of how the product works.

The sales message should be simple and dramatic.  A video or exhibit backwall with a few pictures and copy can tell your story quickly and effectively. Help the booth staff tell the product story with a few key visual aids that highlight the product's most important features and benefits.

Problem 3: How do you follow up with the potential buyer?

Business card drop box 

 Photo: Business card drop box (slot) in a 2X scale prop model of a new medical device.

 Answer: Often several potential buyers show up at a trade show exhibit at the same time.  A business card drop box offers a quick way to get a potential buyer's business card even when exhibit staff is busy with someone else. Provide blank name/address cards, too, and pens to make it easy to fill them out. Consider adding a question or two on the blank card to help qualify the prospect as a potential buyer.

If the objective is to make an appointment with the potential buyer for a followup call, include a graphic that invites the visitor to sign up for a product demonstration. Include a large appointment book to make it easy.

Another option is to integrate a private area or separate office into the exhibit area as a place to close a sale, show more detailed product options, etc.

One technique to close sales is use of show specials: offer a lower price for orders at the show only, making the invitation highly visible.

To wrap up the planning process, ask yourself:

  • Did we pinpoint the product and sales message in the headline?
  • Did we dramatize the product for immediate impact?
  • Is the exhibit uncluttered and geared to a single objective?

If yes, then you are on your way to having an effective exhibit. If you have any questions or would like to discuss exhibit design, a cutaway of your product, a product model, or a larger or smaller than life model contact us at Model Builders, Inc. 773-586-6500 or info@modelbuilders.net .

 

 

Tags: construction equipment models, railroad equipment model, exhibit, interactive exhibit, product cutaway, product model, engineering model, industrial scale model, trade show product models, medical models