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Borrowmeadow Road, Springkerse Industrial Estate, Stirling, Scotland, FK7 7UW

Phone: 01786 464434
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3D printing for aerospace industry

Aerospace

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Flame retardant, robust, lightweight prototypes - perfect for the aerospace industry

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Aerospace

CA Models has been working with the aerospace sector for over 20 years, providing invaluable prototype models that have played key roles in industry developments.  Projects we regularly undertake include:

  • 3D printing SLA parts for wind tunnel aero optimisation.
  • FDM 3D printing fire retardant production parts.
  • Metal Additive Manufacturing (3D Printing) parts with integral honeycomb structures to retain maximum strength whilst substantially reducing weight. 
  • Manufacturing complete 1:1 scale rotating radar systems for customers sales and marketing exhibitions around the world including international air shows.
rapid prototyping  and additive manufacturing for the aerospace engineering industry
3D printing for aerospace engineering . we utilize different additive manufacturing processes to achieve a rapid prototype
3d model for aerospace built using different additive manufacturing methods. These include stereolithography, fdm, sls and metal additive manufacturing
additive manufacturing and 5 axis cnc machining  for the aerospace engineering industry
cnc machining, 3d printing and additive manufacturing for the aerospace engineering sector
3D printing for automotive industry

Automotive

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Engineering excellence in the delivery of prototypes for the automotive industry

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Automotive

Working closely with automotive design teams, we provide a vast array of components, most recently:

  • 1:4 scale SLA ceramic wind tunnel models.
  • FDM 3D printed soluble cores for carbon fibre mould production.
  • 1:1 scale gearbox and differential housings, 3D printed on large volume SLA machines.  A polished and lacquered clear finish revealed internal components.
  • Large capacity CNC milling for manufacture of bodywork and chassis components.
  • 5-axis machining of production suspension-steering components.
  • Metal Additive Manufactured (3D Printed) components with internal fluid-air channels (not possible by means of standard machining operations).
precision engineering for automotive industry using additive manufacturing and cnc machining to manufacture high precision components for automotive customers
additive manufacturing has been used to create this automotive rapid prototype. Technologies like stereolithography and metal additive manufacturing were used.
3D printed motorsport component
Automotive metal Additive Manufactured component which has been post 5 axis cnc machined to spec.
5 axis cnc machine precision engineered motorsport component being inspected by a CA models engineer
Rapid prototyping for aerospace engineering

Defence

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Optical enclosure for Thales Optronics

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Defence

Customer – Thales Optronics

Processes – Metal Additive Manufacturing, CNC Post-Machining, Alochrome Coating, CMM Inspection

CA Models 3D printed an optical enclosure in Aluminium CL31 using our metal additive manufacturing technology.  Tight tolerances and an internal component fitting required post-machining to achieve sizes that were not possible from the metal additive manufacturing process alone.

Our CAD engineer executed extensive modifications to the original CAD data to accommodate the manual finishing and post-machining processes.  

Bespoke jigs and fixtures were made to clamp the components in preparation for post-machining.  5-axis machining was then carried out on the aluminium 3d printed parts to achieve the necessary tight tolerances and precision fit of the mating parts.

The enclosures were treated with an Alochrome coating to seal the surface, thus preventing the parts from tarnishing.

Our CMM inspection service was used to verify sizes and ensure specific drawing tolerances were met.  Detailed inspection reports were prepared and supplied to the customer as per their request.

More images below.

3D printing for aerospace industry
additive manufacturing defense component for Thales which has required post 5 axis cnc machining to achieve a tight tolerance
metal additive manufactured defense part with post cnc machining for Thales
metal additive manufactured 5-axis cnc machined Thales defense component
a 3d printed defense part manufactured using metal additive manufacturing and 5 axis cnc machining to surface areas with tight tolerance
Precision engineered Defense part
3D printing  for medical industry

Medical Device

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Intricately engineered and hand finished prototypes

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Medical Device

Our excellent reputation in the medical sector has been gained through consistent delivery of intricate parts for concept approval, testing and for use in clinical trials.  Examples of recent projects include:

  • Numerous types of handheld monitoring equipment models, utilising the entire range of our prototyping technologies.
  • Multiple vacuum cast products in food-grade materials.
  • CNC machined surgical instruments and assemblies in medical grade materials.
  • Various 3D printed, self-administration drug delivery devices, finished and painted to the highest achievable specifications.

With the addition of a second metal additive manufacturing machine, we will be exploring the ability to manufacture medical grade implants.  More information on this exciting development will be revealed soon.

rapid prototype 3d printed medical model. Created using different additive manufacturing methods and model making craftsmanship.
3D printed Medical prototype. 3d printing technologies like stereolithography and selective laser sintering have been utilised to create the model.
rapid prototype medical device. This 3d model has been made using stereolithography to create a master model. Vacuum casting is used to create the final prototype
medical 3d printed rapid prototype inhaler for product development. 3d printing technology and model making skills are used to create this prototype.
Additive Manufacturing and cnc machining for Medical product development
F1 CAD drawing

Motorsport

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Double water inlet/outlet components for a Formula 1 Team

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Motorsport

Customer – Formula 1 Team (Team name - confidential)

Processes – Metal Additive Manufacturing, CNC Post-Machining, CMM Inspection

CA Models 3D printed the double water inlet/outlet components in Aluminium CL31 material using metal additive manufacturing technology.  This method guaranteed component strength as well as being lightweight.  Another vital benefit of metal additive manufacturing is that the components would be hollow, as required in this instance. 

This process firstly involved choosing the optimum build orientation to achieve the best possible build quality.  The CAD was then altered to provide additional stock on the component.  This alteration is essential when a component requires post-machining.

Once the build was complete, the components were carefully hand dressed then passed to the CNC department.  Bespoke jigs were made to hold the components in place while they were post-machined to exact tolerance specification.  All components were inspected for dimensional accuracy using CA Models CMM Inspection equipment.

More images below.

F1 CAD drawing
Metal additive manufacturing F1 component with 5-axis post machining
Metal additive manufacturing F1 component
Metal additive manufacturing F1 component with 5-axis post machining
Metal additive manufacturing F1 prototype
Metal additive manufacturing F1 components after post processing
3D printing for oil and gas

Oil & Gas

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Subsea training model for GE Oil & Gas

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Oil & Gas

OVERVIEW

CA Models has been supplying the oil and gas industry with sales, marketing and training models since the early 80s. Our very highly skilled engineers and pattern and model makers whose experience is founded on traditional techniques and materials, subsequently adapted to the introduction of rapid prototyping (RP) in the 90s.

Today, the industry benefits from integrating and combining numerous manufacturing technologies - multi-axis milling and turning for the manufacture of precision machined components, as well as 3D printing parts in a variety of materials.

One of the most exciting advances in RP for CA Models is the development of metal additive manufacturing - 3D printing metal parts from CAD data.  

The distinct advantage we have is the ability to build and post-machine RP components in-house. The post-machining process is essential to achieve tightly toleranced bores or features, capable of being interfaced with other machined components and assemblies.

Customer – GE Oil & Gas

Processes – CNC Turning, CNC Milling, Wire Erosion, SLS, Painting, Finishing, Assembly

1:6 scale Subsea Structure Training Models

These models were manufactured using a combination of our multi process and multi material services.

The main structure and all load bearing components were fabricated from machined parts for strength and stability. This method allowed main interfaces to be represented accurately, essential to ensure trouble free connection and alignment with other related equipment. 

Inboard and non-load bearing equipment were manufactured from RP components.  The customer’s CAD data was used to ensure these parts had all of the details and features shown on the full size equipment.

Individual components were spray painted, assembled and fitted with markings to resemble the full size equipment.  The final assembly was then secured to a custom-made base resembling the seabed.

3D printing for oil and gas
Precision engineered 5 axis cnc and additive manufacturing processes have been used to create this oil and gas training model
Rapid prototype Oil and Gas training model. Selective laser sintering and stereolithography have been used to build most of the components.
rapid prototype 3d model assembly for an oil and gas trade show. Many components have been cnc machined or use cnc turning to create the model
A Precision engineered model for the oil and gas industry. Additive manufacturing and cnc turning are the technologies that are used to make the model.
Engineering model for oil and gas industry. created using 3d printing, additive manufacturing and cnc machining are all used for components of the model.
3D printing for product design

Product Design

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World-leading satellite operators SES Design Competition

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Product Design

Customer – SES Satellite Company – Dragon, Calla and Blossom Designs

Processes – SLA, SLS, CNC, Paint Room and Modelshop

SES Satellites approached CA Models to produce three very unique, fully functioning prototypes of design winning satellite dishes.  Each of the three prototypes required components to be 3D printed in SLA and SLS.  CA Models’ iPro was chosen to build the SLA components due to its large platform size 750mm x 700mm x 650mm. Also, the surface finish of the SLAs allow for a high end painted finish necessary for these models.  The SLS components were built in Nylon materials with strong durability for the parts that required structural integrity.

The Blossom and Dragon designs required components to be CNC machined in CA Models’ machining department in aluminium, stainless steel and alloy materials.  Perspex platforms were also CNC machined at CA Models so that all three designs could be mounted once assembled.

All of the components were then hand finished in the Workshop, before being painted and lacquered with two-pack paint/lacquer in our professional paint room.  Finally, each prototype was assembled and mounted onto their perspex platforms.

Prior to shipping, the prototype satellites were packed into bespoke shipping cases which were also built at CA Models specifically to ship the models safely to the customer in Luxembourg.