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Limit concept bottle design prototype

Client: Matter This design prototype model of a bottle was an exhibit for a packaging design show which we produced for Bath design consultancy Matter NPD.  Starting from a 3D CAD model we produced the physical form as a stereolithography model (SLA), from this we took silicone elastomer moulds to vacuum cast both the transparent hollow bottle and ceramic effect top. A metal clip and dummy seal were produced to complete the illusion. The outer surface of the bottle has a frosted surface finish applied, translucent graphics were then added using CNC vinyl cut masks around the base of the bottle to achieve the ears of wheat effect, which actually used the bottle's liquid contents to give a subtle orange glow when lit from below. Many visitors to the show refused to believe this was not an off-the-shelf item we had customised, but we can say proudly that this beautiful model was…

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Glass Screen Clamps

Client: Herman Miller These prototype clamps were machined from aluminium, with moulded 50 shore elastomer inserts added for grip all mounted on a 3D printed, glass-filled SLS base. They formed part of a presentation to show a proposed design for a mass-produced clamp for glass screens.

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Concept Model Fire Extinguisher

Client: Matter NPD, DBA Inclusive Design Challenge The idea behind this innovative fire extinguisher concept model was to make a practical safety device for the home that was attractive enough to be kept in plain sight, while not compromising on its efficacy. Particular attention was given to making it easy to use for people with limited sight, mobility or dexterity. The main body was turned from aluminium and given a subtle etched floral design over a brushed finish.  The red nozzle was a hand-finished SLA part with a high-gloss painted finish while the transparent top and actuator button were SLA parts polished up to give a clear, glass-like finish, subtle texturing being used to clearly indicate how to actuate the mechanism.  A part of the design not shown in our pictures was the inclusion of a simple smoke mask with self-adhesive fixings, which covers the trigger pad and therefore has…

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Working prototype of the Swiftpass Scanner

working prototype of Panik Technology swiftpass scanner.

This working prototype  of a mobile ticketing scanner was one of 20 vacuum casts made from rapid prototyped masters. They were used for fit and function testing before the first-to-market scanner of its kind was launched. The Swiftpass product was designed by Blue Terrapin with electronics by Panik Technology (now Kinneir Dufort).   Vacuum casting is an ideal process for producing low-volume batches of functional plastic mouldings because of its low initial cost and rapid turn-around times.  Using a master model produced by  3D printing or a modified existing part, Amalgam can produce soft tooling capable of producing batches of components such as this hand held device in a matter of days.  This allows rapid evaluation of new designs with minimum cost but can also serve, as in this case, to supply clients with robust, fully functional working prototypes which are identical in quality, look and feel to their mass-produced cousins. We are able to…

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Bathroom Furniture

Client: Roper Rhodes The client asked us to mock up this basin and toilet as a way of fully communicating the design to their Client, as well as being a visual aid for the manufacturers. At this stage the virtual design wasn’t complete so we hand-sculpted the items using polyurethane foam. It was an economic way of producing a rapid result, that was both lightweight and durable.

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The Evolution Digital Shower

Client: Touchlife We were asked by Touchtile to produce parts for a working prototype of their contemporary shower system. The shower's operating system (control tile) is integrated within a ceramic tile, allowing access to all functions via a series of 40 sensor-responsive buttons, which appear as part of the tile.We produced these water-tight replicas from 3D printed masters, which allowed the complex electronics to be tested.

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XDK Development Kit Enclosure

Client: Xmos XMOS Semiconductor is a fabless semiconductor company that develops a range of microprocessor products. This XS1-G development kit enclosure is a low-volume, highly customisable design, used in a variety of configurations to house the sophisticated electronics. Product design consultancy Brightworks directed the look and feel of the casing and then approached us for prototyping. All three companies worked to finalise the design, which we translated into CAD models and SLA masters. These were used to produce soft tools and several runs of enclosures. We also produced a range of laser-cut acrylic insert panels for the various connector configurations, and screen-printed fascias which incorporated an illuminated glowing blue Xmos logo.

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‘The Hydrant’ Water Bottle

Client: Hydrate for Health Following a serious spinal operation in 2005 Mark Moran was unable to move for a couple of days and then had very limited movement for a short while afterwards. During this time, bed-bound and stationary one of his main problems was getting enough to drink. The reason it was such a problem was not a lack of water, far from it, but the fact that the jug and cup were on a cabinet next to the bed and, as movement was so difficult, he was unable to get a drink unless a nurse was called to assist. This, coupled with the very hot and dry hospital environment, meant there was a very real danger of becoming dehydrated. Mark was so convinced that he could provide a solution to this very real problem that he quit his job and bet his house on the idea. He approached…

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Prototype Folding Bike for Schwinn

Client: Cycling Sports Group Amalgam's prototype specialists worked closely with Cycling Sports Group from the USA to produce this concept quick folding bike prototype. The brief was for the bike to have many innovative features, including a quick release mechanism for a shopping basket or child seat, a built in stand and self-centring steering. To evaluate and test the various features, a fully functional 'soft' version or "Pre-prototype" was mocked up using CNC machining and FDM rapid prototyping plus several more traditional prototype model making methods. The next stage was to convert sketches into 3D CAD using Solidworks, and replace plastic sections with aluminium extrusions and machined elements. Our engineers welded together all the metal elements and the frame was given a lustrous high gloss top-coat. This finish, combined with the innovative design and aesthetics created a truly show-stopping product in time for it's place at Eurobike 2012 in Germany.

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City of Justice, Madrid

Client: Foster + Partners A 1/500 display model of Foster + Partners’ designs for two buildings - the Regional Appeal Courts and the High Court - within Madrid’s new Campus of Justice. The new scheme is designed to promote the value of transparency, therefore a white finish, clear elements and a wooden base were used to best reflect this in the model.

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