Project: Bell Helicopter 417 1FR

Client: Seymour Powell

Our mission: To build a model of the new helicopter that had a high impact and impressive finish, within a short time frame, for exhibiting at Heli-Expo, Las Vegas.

How it was made: We began by taking Seymour Powell's redesigned Alias 3D CAD models, utilizing VX Visions software to model and create tool paths. This enabled us to CNC machine parts and female moulds to produce GRP panel work to start reconstructing the helicopter.

Having first removed any existing interior panel work and equipment, we cut the body of the fuselage that was supplied into three sections. These sections were then extended to give more leg room and extra space in both the cabin and cockpit. The opened joints were given a reinforced aluminium structure. We then treated the fuselage exterior to a highly finished re-spray.

Next we worked some real magic on the finishing of the interior. New panels and equipment were installed. New seats were created, trimmed in high quality leather with accurate detailing. Full mood lighting was integrated into the cabin floor, roof, seats, handles and cockpit. And finally we fitted a fully operational DVD system.

The whole project took us a mere 10 weeks. We were able to achieve this through close communication and a high degree of trust between ourselves and the client.

Client: City University

A team of students competing in a race series known as Formula Student that promotes careers and excellence in engineering by challenging students to design, build, develop, market and compete as a team with a small single seater racing car. It is run by the Institution of Mechanical Engineers, in partnership with the Society of Automotive Engineers and the Institution of Electrical Engineers.

Problem: The intake manifold design had become extremely complicated, due to its complex shape and a rule imposing a restrictor in the airflow. This made the design of the new intake manifold system essential to the design of the racing car, as it would enhance the performance of the engine..

Solution: We were able to create the model using SLS rapid prototyping technology with an aluminium filled nylon material capable of withstanding 150°c, but whilst it increased the engine power, it produced some unexpected results for Formula Student. There were difficulties with extra air flowing back into the engine through the gap between the engine block and the bottom of the prototype runners, so we modified the inlet runner to perfect the design. Our assistance helped the City University Team to develop their engine and significantly improve the power and torque it could deliver, allowing the team to anticipate how the newly designed racing car would perform.

Project: Thorasic Artery with an embolism

Client: Classified

How it was made: First we produced an SLA master of the core and gave it a gloss finish, before producing a silicon mould. Next we made wax cores, which we measured to maintain the material thickness and monitor and avoid shrinkage.

We then CNC machined the external tool from PU model board and gave it a gloss finish. After that we machined the core support pins from aluminium to ensure accuracy when positioning the core in the tool.

The wax core was fitted into the hard tool and silicon was poured into it. When this had set, we removed the silicon part with the wax still inside.

Finally we gently warmed the core to melt the wax. The gloss surface finish was unaffected, so the model maintained the necessary clarity and detailing.

'Ogle models has always risen to our challenges, producing complicated moulds to a very high standard. The technology and expertise they have to offer is very exciting. Their silicone moulds, created from 3D CAD files, have been important in our development of new products.'

Project: TriStar C Mk 2 aircraft

Client: Marshall Aerospace

Their objective: Fit new Defensive Countermeasures Systems to the TriStar

Our mission: To manufacture composite test canoes for fitting onto the aircraft, to check if any vortexes were created that would affect the re-fuelling hoses.

Problem: The materials used had to withstand the conditions of flight and the parts had to be aerodynamic.

Solution: We produced the canoes using CNC machined female moulds from which epoxy composite structures were produced with fibrelam and aluminum strengtheners. Laser sintering was used to produce nylon parts for the inspection hatches and turret. The sintering process meant a fast turn around and produced parts that were given a smooth finish for aerodynamic testing.