This device was tooled from a styling model in Right Hand form and later Reverse Engineered without additional design input using reversible templates enabling a Left Handed variant to be produced. Both are now in regular production on a small batch basis. Cellular Mouldings also offer the opportunity to assemble electronic units and the items shown are supplied fully assembled and ready to plug in.
Large Cover
This cover is a complex structure with a highly profiled display facia. In order to maintain uniform following wall thickness the tooling incorporates several loose pieces to create the necessary undercuts. Low volume production is in place for the life of the product.
DNA Testing Device
This device is in medium volume batch production and comprises a functional cover with mounting points for a heater.
The chassis is also a highly functional device carrying peristaltic pumps and drive units.
Side cheeks are cosmetic only and serve to lift the aesthetics of the metalwork associated with the base.
Brake Tester Housing
Designed for use in a commercial garage environment these covers house a device for testing the efficiency of two wheeled vehicles on a "rolling road". The high gloss paint finish is in a durable Polyurethane giving excellent wear and finger mark resistance
Flight Simulator
This training system for the aeronautic industry serves as a flight simulator.
The main moulding is an unusual shape as it overlaps and overhangs the support bench.
It also has to carry a substantial monitor on its top surface.
Scientific Instruments
These mouldings are finished in a wide variety of colours for different markets. It is interesting to see the pastels, metallics and other finishes being used in scientific environments. It makes a change from the standard computer beige/grey colour.
Night Viewer
You may have seen this used by James Bond in a recent movie. The product was test marketed in Cellular Mouldings' mouldings before making a commitment to hard tooling for injection moulding. Market circumstances changed and the product continued to be supported for a period as the major investment was deferred. Recent developments at Cellular Mouldings enable quite high volumes to be economically produced. (Up to 100 sets/week of small items).
Military Sights for Virtual Warfare
Illustrations are part of a whole range of complex mouldings.
Initially the prototypes were produced and evaluated.
At a later date substantial production run followed using the same original tooling and without any re-tooling charges to the client. Tooling in Cellular Mouldings (IPT)T (Immediate Production Tooling) exists for the life of the product, which in some cases can be tens of years.
Flexible
The production materials used by Cellular Mouldings include semi-rigids, fire retardant grades, high heat distortion, medium and light foams and certain grades of flexible rubbers. All material for both components and tooling are Polyurethanes formulated specifically for the process. Short life silicone tooling is not used in the Cellular Mouldings (IPT) T process.
SLA to Component in Record Time
Customer supplied SLA models were tooled, with production castings finished and delivered in 11 working hours. There is no entry for this in that famous book of records but even this performance is not the fastest Cellular Mouldings can react if the need and the planning is in place for Rapid Product Development.
Production rates of 25/week from single tooling can follow indefinitely without further tooling charge for the life of the product.
Mixing Desk
In order to fan out the individual desks a 3-degree "wedge", rather like an enormous slice of cheese, was inserted at each angle change.
The moulding replaced metalwork and expensive cosmetically finished fibreboard items generating a cost saving in both components and assembly time. An additional advantage was that the moulding also carried cable supporting, desk to desk access points.
Moulded Top with Logo
The move from metal cases to a custom moulded case presents, among other opportunities, the chance to incorporate a distinctive logo. Often this saves the cost and inconvenience of separate labelling but more important in many cases for producers of relatively low volume products (less than say 1000 per annum) it creates the right impression with customers, particularly in export markets, who often view metal-boxed products as temporary developments. With Cellular Mouldings even very low volume products can benefit from custom moulded cases with minimal tooling investment.
Anaesthetic Dispenser
This product was only intended to be prototyped in Cellular Mouldings to the extent of ten or so sets for final evaluation and publicity launch however the injection moulding tooling had a major hiccup (like lets start again!) and the launch produced orders from major European hospitals. A "one shot" production run was initiated to satisfy delivery promises resulting in Cellular Mouldings' mouldings seeing service in arduous medical environments and subject to the type of conditions usually only satisfied by top specification injection moulding plastics.
Entertainment Industry Components
Large facias (2 metres or so) do not present a problem. Working from CAD data SLAs are generated and these can both be cosmetically dressed and used for launch or evaluation, or tooled up for production depending on the client's requirement.
Cosmetically Cellular Mouldings can finish in a wide variety of paints including deep gloss metallics, simulated stainless steel or aluminium and soft- touch or velvet textures.
Resin Tooling for Investment Casting Waxes
Although not yet a mainstream activity, Cellular Mouldings have successfully created several resin tools for wax pattern generation.
Liaison with selected foundries is continuing and this market area is considered worth developing further.
Ticket Machine
The designer of this range of machines utilised the facility offered by Cellular Mouldings to the maximum. Some parts of the master patterns were made by SLA, some machined and some fabricated conventionally.
Complexity and timescales dictated the split between the techniques. Also, the availability of final paper drawings, a facility that is often bye-passed in CAD, is essential when traditional methods interface with stereolithography.
Nuclear Detector
A hand held nuclear detector with an incorporated speaker grill.
Cut and Clinch Machine Covers
In addition to the large cover shown separately this device utilises a number of Cellular Mouldings panels for decorative and functional purposes on the front assembly.
Cup Station
This cup station for a niche market series of drinks dispenser was produced in two variants. The one illustrated carried a stainless steel panel over the lower section. This was later moulded as a plain surface that was painted with stainless steel paint, so saving a component.
Rheogoniometer Housing
Rheology is basically the quality of a material or substance. Liquids and high viscosity fluids (Toothpaste or liquid foods for example) in this case are tested for change in viscosity with time. The lower part of the device is a massive metal casting for stability. Cellular Mouldings supplied the two top covers also a facia and bezel for the control system.
