Contactscale combines 30+ years expierance in composites with today's digital workflow. CS does this through our large scale Zystech cnc routers. We machine parts as long as 19-5FT. These foam parts can be coated and used to build molds from. Our techeque is both fast and cost effective to design and prototype a product.
We generally break all jobs into these Phases allowing the customer to pick and choose their leval of envolvement.
Phase 1
●Design Sketches
●CAD and Solid Modeling
Phase 2
●CNC cutting (A full 3D shape)
Phase 3
●Plug or Buck finishing (Coating and finishing the part. Getting it ready for molding)
Phase 4
●Mold construction (One or more piece molds)
Phase 5
●Molding (Single part or full OEM production)
• Consulting/ Education
• CAD Design/ Rendering
• CFD Simulation/ Thermal Testing Prototyping
• CAM/ CNC Rapid Prototyping
• Plug/ Buck Construction and Finishing
• Mold Construction
• Molding/ OEM Manufacturing
• Training/ Support
Starting a project.
These are parts that were first sketched out by hand and sent to us. We converted the drawings to CAD and emailed back a renderings of the finished parts. Once any changes were made and are approved the parts are then machined to scale and sent to the client.
A full scaled machined foam part is a great cost effective way to proof your design. These can be taken and turned into a plug or buck for molding.
CFD testing for certifiaction.
Contactscale has a wide varity of CNC machines.
The Z1 Zystech 5 axis cnc router is capable of sizes up to 20 feet long, 12 feet wide and 7 feet tall can be cut with a single toolpath. Plus 5 other 3, 4 and 5 axis production machines.
We also do production machining and cutting. (Pricing Call or Email Us)
Here is just some of what we cut and machine.
• 1/4 scale vehicles and architechtual structures
• Full scale vehicles, wind turbines, aircraft and boat hulls
• Custom CNC Hot wired EPS Blanks: Surf, Windsurf, Paddle and SUP Boards
• CNC, Computer Shaped Blanks
• CNC Fins and Scegs
• CNC Paddle Machining
• Canoe Plug Machining (See Gallery Page)
File type we can use:
• STL, VRML, IGUS, DXF, DWG, STEP
The finishing begins
After any part is machined from either EPS or tooling foam it must be sealed and primmer. This can be time consuming and is very important. The finished surface will reflect what the final part will look like. This is the final step prior to building the mold.
Any part any Size.
Whether we are building a one piece or five piece mold it's takes experience. Every mold we build generally will have the ability to replicate 1000+ pcs.
The resin types we use are epoxy.
TIP : ) Molding options for a single part or small qty runs. We have developed a techniques that saves money on small runs, lightweight one off molds.
(Pricing Call or Email Us)
Levals of production.
We mold all kinds of parts and in all sizes and with all types of materials, Fiberglass, Carbon Fiber, Kevlar and even Spectra Cloth.
The resin types we use are epoxy.
• CAM ( Computer Aided Machining )
• CNC ( Computer Numerical Control )
• Epoxy Resin vs. Polyester Resin
In any high-tech structural application, where strength, stiffness,
durability and light weight are required, epoxy resins are seen as the
minimum standard of performance for the matrix of the composite.
This is why in aircraft and aerospace applications, as well as
offshore racing boats, epoxies have been the norm for years.
However 95% of pleasure boats under 60 feet today are still made
with polyester resin. The main consideration for materials selection
for most composite builders is cost, with performance and more
importantly value for money often being a secondary consideration.
As a general rule epoxy resins are twice as expensive as vinyl ester
resins and vinyl ester resins are twice as expensive as polyesters.
Since the resin can constitute 40 to 50% of the weight of a
composite component, this price difference is seen as having a
significant impact on the cost of the laminate.
However, when considered against the cost of the whole structure
(the car) the cost is relatively insignificant, and the value of higher
quality and long term gain of better durability (therefore better resale
value) can be tremendous.
What contributes to this better value…..?
Epoxy resins have performance advantages over polyester and vinyl
esters in four major areas:
• Better adhesive properties (the ability to bond to the
reinforcement or core)
• Molding tolerances (Very little shrinkage)
• Superior mechanical properties (particularly strength and
stiffness)
• Improved resistance to fatigue and micro cracking