Rapid 3D Prototyping for Churchill

During this phase we assess your requirements to determine if we are best to design your model from scratch using 3D CAD tools, 3D animations tools, or perform a 3D scan an mock up model.

While 3D scanning sounds like an easy option, it is not perfect, and requires much cleaning up of the model. Further it produces a file with point cloud data, which then must be converted to a typical CAD file (e.g. .igs, .stp, and/or .stl). It is because of these reasons, it is generally quicker to create the design from scratch (unless the target requirement is just to reprint the scanned object without any additional design features - which is a service we're not keen on providing).

In terms of electronics - generally we design custom electronics to get the unit cost down, but in some cases we might use off-the-shelve electronics (e.g. Proof-of-concept prototype).

Plastic mechanical parts will likely be 3D printed via various methods such as Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS), Multi Jet Fusion (MJF) or CNC'ed in some cases. The material options are kinda endless from rigid to rubbers, such as ABS, PLA, Polycarbonate (PC), Acrylic (PMMA), PET, PEEK, Polyamide aka Nylon (PA), Glass reinforced nylon (PA66+GF), Polyurethane (PU), Polypropylene (PP), Polyvinyl Chloride (PCV), Thermoplastic Elastomer (TPE), Thermoplastic Olefin (TPO), Thermoplastic Polyurethane (TPU), PEBA 2301, Nitrile Rubber (NBR), Polytetrafluoroethylene aka Teflon (PTFE) and more. There are also various finish options such as transparent, transulent, colours, electro-plating, reflective mirror, and screen-printing graphics.

Metal mechanical parts can be 3D printed also, however in our opinion CNC is still the better option. The material options are also kinda endless such as aluminum (AL), steel, stainless steel (SS), brass, etc. There are also various finish options such as blackening, electro-plating (Chrome-plating, Nickel-chrome plating, Zinc-plating, Galvanizing), anodized (black, matte clear), and chromating conversion.

We've also made prototypes using materials such as Carbon Fiber, Fibreglass, Glass wool, DuPont, Vectran, conductive thread, and look forward to playing with Graphene one day.

Electronic parts will involve manufacturing of bare PCBs, then assembling PCB surface-mount (SMT) and through-hole (THT) components via soldering methods such as a stencils, reflow oven, IR heat lamp, hotair rework station, soldering iron, etc.

Hardware bugs are likely, and we'd hack things to make the working prototype. During this process we'll make notes on the design changes required for the next revision.