Introduction

In April 2023, Stephanie Pisharody, Head of Philanthropy at Essex & Herts Air Ambulance (EHAAT), approached Prototype Projects with a unique request: to create a detailed helicopter model that would be a unique thank you in recognition of people making significant gifts to the charity. EHAAT provided an STL file of the desired helicopter model, but unfortunately, its condition rendered it unsuitable for further processing. Undeterred by the initial setback, our team embarked on a journey to transform the digital design into a tangible and visually striking representation of the life-saving services provided by the charity.

Challenges

The task at hand presented several challenges that demanded innovative solutions. Firstly, the STL file provided by EHAAT was in a state that precluded direct utilisation for manufacturing. Additionally, achieving a high level of realism and accuracy in the final model was imperative to effectively communicate the essence of the air ambulance service. Overcoming these challenges required a multi-faceted approach and close collaboration with external partners.

Solution

Our approach to addressing the challenges involved a series of strategic steps:

1. Initial Printing and Preparation

Recognising the limitations of the STL file provided, we opted to print the model in its current state. The printed model underwent meticulous sanding and priming in our Rapid Prototyping (RP) workshop, ensuring a smooth surface finish conducive to accurate scanning.

2. Scanning and Reverse Engineering

To progress further, the prepared model was entrusted to an external partner equipped with state-of-the-art scanning technology. Their expertise enabled them to scan the physical model and generate a Step file, which served as the foundation for subsequent CAD modelling.

3. CAD Modelling and Detailing

Armed with the Step file, our trusted partner, Cambridge Design Technology, collaborated closely with us to refine the model. Their proficiency in CAD modelling enabled the addition of intricate details, addressing discrepancies, and enhancing the overall realism of the design.

4. 3D Printing the Final Model

Leveraging our Neo SLA 3D printing technology and utilising SLA Xtreme material for superior quality, we embarked on the production of the final helicopter model. Despite encountering challenges such as window size discrepancies, internal features, and scale issues, our team remained resilient, iteratively refining the design to achieve the desired outcome.

5. Finishing Touches

With the final models in hand, our attention turned to the crucial task of applying finishing touches. Each model underwent meticulous painting to accurately replicate the colour scheme of the charity’s helicopters. Furthermore, transfers, for which we designed the artwork, were carefully applied to enhance authenticity. Finally, the models were mounted on laser-cut bases, ready for display.

Outcome

The collaborative efforts between our company, Cambridge Design Technology, and EHAAT culminated in the successful creation of highly realistic and detailed helicopter models. Despite the initial challenges encountered, the project’s success underscored our commitment to delivering innovative solutions tailored to our clients’ unique needs.

Stephanie Pisharody said:

“Collaborating with Prototype Projects on our helicopter model project was truly remarkable. Despite initial challenges with the STL file, the team’s innovative approach and dedication shone through. The final helicopter models exceeded our expectations, showcasing the professionalism and attention to detail of Prototype Projects. These models now provide a unique way of thanking people who have made outstanding gifts to the charity, continuing the vital work of Essex & Herts Air Ambulance. We are truly grateful for the support of everyone at Prototype Projects and Cambridge Design Technology.”