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Advanced FUD Post-Production [message #45007] Wed, 07 March 2012 06:03 UTC Go to next message
avatar ahncinema  is currently offline ahncinema
Messages: 15
Registered: October 2010
Go to all my models
Junior Member
I wanted to share with everyone the latest prototype of a project I have been working on over the last year. The piece itself is of limited appeal (a pinhole lens for motion-picture use), but I thought the post-production process might be of interest to other Shapeways users.
The bulk of the piece is FUD (or, more precisely, FD). It arrived waxy, oily, and a little rough.

http://www.ahnelson.com/pinhole/DSC_1529

There's been a lot of discussion on these forums about how best to remove the wax and oil from these models. I had great success with a soft toothbrush and a cup of warm soapy water. I turned the piece on a lathe and sanded many of the surfaces, scrubbing in between passes to make sure no material built up. The result was much smoother and cleaner in appearance.

http://www.ahnelson.com/pinhole/DSC_1547

Though fantastically detailed and accurate, the translucent and brittle nature of the FD material is a drawback. I decided to have the piece metal-coated by Sean Wise at RepliForm, in Maryland. Sean sprayed the model with a very fine abrasive before applying a thin .003" layer of nickel to the surface. This provided a tough shell without sacrificing the fine details and careful measurements.

http://www.ahnelson.com/pinhole/DSC_1714

As you can see, the build lines that were not sanded away are still visible, but the exterior is now quite tough and less prone to chips or scarring.

At this point, all that remained was painting and installing a little bit of hardware. I masked off the parts that I wanted to remain silver and airbrushed the exposed surfaces black. Once dry, I assembled the finished lens (with CNC machined aluminum mount) and shot some test footage (which can be viewed at https://vimeo.com/37637102). Below are some photos of the finished piece.

http://www.ahnelson.com/pinhole/DSC_1764

http://www.ahnelson.com/pinhole/DSC_1770

http://www.ahnelson.com/pinhole/DSC_1773

And here it is mounted on the camera.

http://www.ahnelson.com/pinhole/DSC_1616
Re: Advanced FUD Post-Production [message #45013 is a reply to message #45007 ] Wed, 07 March 2012 11:36 UTC Go to previous message
avatar ChristelH  is currently offline ChristelH
Messages: 58
Registered: October 2010
Go to my shop
Member
I work here
Hi Alex,

The model is looking great! I also love the way it has been sprayed! Good job Smile

Cheers,
Christel
Customer Service Agent
Shapeways


Best, Christel Maurmair Customer Service Agent Shapeways

 
   
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