Many factors need to be considered when using various materials. During production of a 1:16 scaled wind turbine model, the amount of Ureol being used was adding unnecessary weight to the model. This was overcome by excess material being machined out.

As the main base was CNC machined in two halves, this made accessing and removing the un-required material easier for our model makers. The space gained inside the base also provided us with a slot for an aluminium support tube to provide stability to the entire model.

Using the 3D CAD files supplied by our customer, a majority of the wind turbine was machined from Ureol – a high density foam – including the main base, nose cone and rotor arms representing propellers. A triangular base was laser cut from steel, and the more intricate details such as the balcony sections were manufactured using SLA, a process involving building up layers of resin.

In order to achieve an excellent finish, the preparation of the surfaces prior to painting is extremely important. The entire surface is rubbed down and polished by hand, this process removes any visible join lines and machining marks. The model was then undercoated to provide an even layer, painted with gloss paint and finally lacquered to attain a highly reflective surface. The final stage of manufacture was to assemble the model using dowels and adhesives, and to add the customer’s company logo and window graphics.

To ensure the model reached our customer safely, a custom-made flight case was produced for protection during transit, and the model finally left us by designated courier for an exhibition in Poland.