Research and Development

New Products and Subtractive Rapid Prototyping (SRP)

We have decided to take a look at some new product ideas to compliment our existing range as well as going back to look at some old development projects that were not put into production due to the manufacturing costs at the time.

To this end we have now invested in 3D scanning and milling equipment as well as 3D CAD software. As well as SRP the equipment is also capable of small batch production runs.

Examples of some new products will be:

• Balance weights
• Connecting rods etc.
• New wheel moulds

Examples of some old development projects will be:

• Gear boxes
• Motor bogies
• Side frames

As a test of the scanning option, we scanned two rail chair masters which were made some years back now. The results from the scanned masters can be seen in the 3D images below.

2 Bolt Chair

3 Bolt Chair

The above 3D images were scanned at a resolution of 0.25mm per step in both the X and Y axis. Total scan time for each chair was around 3 hours. The best resolution would be 0.05mm per step, but would also take longer to complete the scan.

Once items like the chairs have been scanned or drawn from scratch it is fairly simple to use the milling option to reproduce the item. It can also be scaled and modified as required.

More details will be posted here as and when we have them.

Examples of some of the work carried out on the 3D plotter.

Heljan Class 14 conversion | Goods Shed Subframe

Below are some photos of the work carried out on the 3D plotter for the new Heljan Class 14 conversion.

	Drawing of the profile for creating the template for the drive crank on the Heljan Class 14. This template is 8X size and is produce on a CAD programme, which also drives the 3D plotter.
	Drive crank template being cut.
	The completed template ready for use. This template is 8x size and will be reduced down to the required 4mm scale on the die sinker.

Below is a photo of the work carried out on the 3D plotter for a Goods Shed subframe. This was work carried out for a customer who is scratch building 'Llangynog Goods Shed'. Cutting these items on the 3D Plotter has made the construction of the subframe easier and reduced the number of parts required to get the same result.

The kit of parts that make up the Goods Shed Subframe have been cut from 1.5mm plywood. The parts are to 4mm scale.

---

If you have any thoughts, comments or questions on the above, then please contact us, either by E-mail at enquiries@ultrascale.co.uk or via the Feedback page.

If any one has suggestions for products that they would like to see available, then let us know and we will consider the possibility of adding it to our range.