77” Enterprise E
3/2010 - 1/2012
Last Update: 1/2/2012
Our grandest assignment to date, in that this miniature will be the result of computer aided design (CAD), from start to finish. The initial overall form has been drawn in Rhino 4 to match the miniature seen in the Star Trek movie Nemesis. The overall form is then broken into sub assemblies with the Aztec “layering pattern” grown directly onto the skins. This will serve the later painting stages as an exact guide for placing the masking stencils. All patterning is then output for rapid prototype development or “grown” to create master patterns for molding and fiberglass lay-up. Thus the geometry is very exacting, making these parts highly reliable for an assured fit. Next update will feature the first rapid prototype patterns for the main upper and lower saucer patterns, intended to create the open faced lay-up molds.
Image 1 (left) is a virtual representation of the lower saucer pattern with all rapid prototype patterns in place as well as the acrylic backing plate. The second image relates to the upper saucer and is a revision of the upper column (picture 5) where all the Aztec patterns were removed. This allows for ease of clean-up in the pattern. The middle image is the rapid prototype patterns as they were received from FineLine prototyping company, prior to clean up (putty work). Last two images feature the rapid prototype parts atop the acrylic backing plate. All elements to yet receive the styrene half rounds and .020" styrene laser-cut plates (outer perimeter acrylic backing plate) pattern work.
Finishing the lower saucer master pattern, with the half-rounds being added. All rapid prototyping window parts and seams are puttied closed. Notice size and scale of saucer as Matt Asanuma fine tunes the putty work on the last of the seams. Last two photos on right show the upper saucer base shape, Computer cut from model plank (medium density foam). Over top of this form, the rapid prototype resin detail plates will be added.
Mike Asanuma places vinyl cut window masks to the lower saucer pattern, over which many layers of primer will be applied. After which, the masks are removed leaving window openings to be molded into the lower saucer pattern surfaces. Rear detail plates and close-ups of the window masks. Last photo shows the finished pattern primed and ready for molding.
Far left – Lower Saucer fiberglass rubber lay-up mold, into which the translucent castings will be made from. Multicolor Upper Saucer detail plates layout, which serves as an assembly guide for creating the master pattern. Center is a close-up of the plates as they are developed in 3D before being sent out to a rapid prototype house for "growing" in physical form. Second to right – CNC model plank support form with the first group of grown surface detail plates. Right is close-up of the center picture area – cleaned up and primed, finalized for pattern assembly.
Left shows all the major grown plates test fit into position. Next two pictures show the completed upper saucer pattern, with all surface plates joined and seamed together. Right picture shows the next phase of patterning; the layout of the secondary hull CNC foam blocks. The secondary hull will be made up of three major sections – two upper portions and one lower belly.
Left picture is the entire ensemble of Secondary Hull CNC foam blocks. Next two images show hangar bay – fantail section, and the front intersection where the lower half starts into the deflector dish. Right two pictures show the surface detail plates that surround the upper CNC foam blocks.
Left – completed upper saucer hull skin pattern adjacent to its CNC foam support unit. Both will be joined together the create the master mold. Second to left are the main secondary hull CNC foam portions that are placed together for inspection of fit. Center shows the left and right main assembled sections with the lower belly portion at back of table. Tan object is rear grown fantail doors pattern. As with other sections of this ship, smaller detail areas are grown and molded as separate add-on sections. Right - lower belly skins after finalization in the computer. From these files, the final 3D skins will be grown.
Left to right, upper and lower views of the machined aluminum armature support system, onto which the interior LED light boards, electronic chipsets, and fiberglass outer shell, will be attached to.
