As we designed out features many weeks ago, we engineered into the structures hard points to mount, join and lift each feature. These were located precisely in order to achieve a balanced and safe load as we lifted each piece. On the bottom or end of each piece is a place we can bolt it to a custom size pallet which is designed to slip into a shipping container and not allow side to side movement during the 11,500 kilometre journey to Dubai.
It is hard to believe that it was only seven years ago I witnessed a CNC router in action for the very first time. I was fascinated with what I saw and simply had to have one! Although I had been in the creative end of the three dimensional sign business for most of my life I didn't really know what I would do with one - but I just knew it could do fantastic stuff.
Through extensive research and LOTS of hands-on practice I quickly found out that my MultiCam router was capable of just about anything imaginable.This journal will chronicle that journey to date and continue each week with two or three entries as I continue to explore just what is possible with this wonderful tool... -dan
Tuesday, June 28, 2016
We've found the MultiCam CNC plasma cutter a very handy tool to create all manners of brackets, lifting lugs and joining connections for the Viking ship features we are creating for Motiongate in Dubai. One size and shape does not nearly fit all.
Saturday, June 25, 2016
In years past we would have built a piece like this all by hand. We would layout the piece by hand and then with a handheld plasma cutter would have cut out the sheet metal. All holes would have been hand drilled. As you can imagine it was slow and involved lots of grinding to smooth out the edges. The upper section of the keel would have been hand formed in pencil rod and then welded in place. The blades on the keel and axe would be hand paid out and plasma cut as well.
On this project everything was designed in EnRoute (in minutes) and then sent to the Multicam CNC plasma cutter. The many pieces were cut in a few more minutes- complete with the many holes. There was minimal grinding to touch up the edges. Knowing the pieces were very precise meant we simply had to line up the edges of the back and front and then weld away. Everything fit perfectly and was nice and square. As you can imagine this saved a great deal of time and labor!
Friday, June 24, 2016
Using EnRoute and our Multicam CNC plasma cutter has allowed us to put in an incredible amount of detail into the Viking ship project for Motiongate in Dubai. The battle axes are a great example. It was a quick process to design the files using EnRoute. It boiled down to a simple outline of the axe and then the detailed pattern cutout. A second piece of sheet metal was cut to weld behind the pattern. When welded up it gave the illusion of engraved metal. The wedge shaped pieces which were welded in to give the axes a taper were also created using EnRoute and the MultiCam CNC plasma cutter.
Today we did the last of the painting on the target features and the axes look absolutely fabulous!
Wednesday, June 22, 2016
It is always interesting to watch the steps of each piece we create. First, there's the development of the idea on paper and on the screen, sometimes with small scale models. Then the piece goes through the engineering stage, to make sure the structure underneath fits inside and holds everything up securely. Then it's out to the shop to begin construction. Steel tubing is cut to length and the welding starts. For most of our pieces the plasma cut steel is designed as we go through the build process. Measurements are taken and then its back to the office to design the pieces in EnRoute. They are sent to the MultiCam CNC plasma cutter to create the piece and then it is welded into place to begin the process anew. And so it goes for weeks.
Once the structure is complete we attach the lath and then trowel on the concrete. this is carefully hand sculpted. After the concrete cures it is time for the painting crew to do their magic. As with all of our projects we do not skimp on the paint. A minimum of three coats of base colours are applied before we begin a series of glazes, and dry brushing to gradually bring the piece to life. After many weeks of hard work the piece suddenly comes to life. Our skillful crew of talented painters blend the warm colours on the wood and cool colours on the metals and rocks to create absolute magic. It's now looking like the movie, 'How to train your dragon'.
Tuesday, June 21, 2016
Work continues on the Viking ship project for Motiongate Park in Dubai. With the deadline quickly approaching the entire crew is working hard to finish off the features.The piece closest to finish is the large target. The last coats of the base colours were painted on yesterday.
That meant we could apply the glazes today. The painting crew worked in teams, liberally applying the brown and dark grey glazes and then judiciously wiping them off. This process takes advantage of and highlights the textures and cracks. The plain grey instantly turned into believable rock.
Certain areas were left very dark or even second coated to make them look deeper.
Once the glazes were done and dry it was time to go back and apply even more magic. Lighter colours were dry brushed on highlighting the tops of the rocks and the deep texture. Then we sponged on various shades of greens, greys, tans and oranges to create believable looking moss. More dark glazes were brushed on to create streaking and aging. And some various colours were flung on with wet brushes to create more texture. The process looks pretty random but it takes a lot of practice and skill to get it all looking right.
As soon as the rockwork was dry it was time to take off the upper sections. We have to build stands for all the pieces. Next week they will be stuffed into containers and sent off to sea for their journey to the middle east.
Friday, June 17, 2016
In the years previous to our getting the MultiCam CNC plasma cutter we spent many, many thousands of dollars having a local machine shop cut steel plates which we used in the building of our features. The plates are mostly used to bolt welded steel frame sections together and for mounting the features in place when they get to their final home. With EnRoute software and the MultiCam plasma cutter now handy we can create the plates on demand and in any shape of size we might need. We also make hundreds of other pieces that are used throughout our creations and sometimes in all welded steel features. With the use we now get out of the software and machine going back to having someone else do the cutting would be impossible now.
Thither than simply throwing a 4'x8' sheet of steel on the machine and fill it with plates, we now make our plates with scrap steel. The plates now only cost what it takes to run the machine, a few consumables and the man to run it. The fact is that when we cut parts for the Viking Ships (or whatever else we might be fabricating) the irregular sized and shaped leftovers add up in a hurry. These scraps need to be taken care of one way or other and they can't simply sit out in the weather gathering rust until we need them for some small piece. Shop space is too valuable and in short supply to store the bulky pieces there. The solution is to create three or four files of the various sized and shaped brackets and plates we use most often and cut them from the scrap. The rest of the waste steel will go into the recycle bin.
There hasn't been a lot of routing done in the shop over the last weeks as we concentrate on the extremely large Viking ships and target features for Motiongate theme park in Dubai. We are making great progress however. Both ships are now out of the shop getting their final framework welded into place. They are just too large to do inside the shop building. The two big mast assemblies head off to the galvanizers today. The large target feature is also out in the parking lot getting it's final paint. We continue to create cutting files and the MultiCam CNC plasma cutter is busy churning out little bits and pieces of brackets and lifting lugs to finish things off. We hope to send off the first pieces of the first ship off next week to the galvanizers and then the push to complete the sculpted concrete will begin.