Large Scale Models.... The MANLY version!

 
  WUISKE Assistant Commissioner

G'day All,
Recently we were contracted to complete several models in an impossible time frame. Being up for impossible challenges, we accepted the challenge and now we are part way through it.
The first part of the project was to paint and detail a 1:5 scale bogie that was made using rapid prototyping.
The second model is an Ore Car that should look vaguely familiar to some here. This model has been produced at a scale of 1:10.
Due to the size of the machinery involved and the enormity of the models they have been produced at a very low resolution. Even at this resolution, the ore wagon below still took TWO WEEKS to print! There are more models coming too us but as I type this, they are still printing, and have been for nearly three weeks!









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  Hendo Deputy Commissioner

Wow!
  Aaron Minister for Railways

Location: University of Adelaide SA
Have you painted the ore car or is that the natural printed finish?
  ALCO4401 Train Controller

Location: On the Branch waiting for a train order, west of Tarana
Adam,

I am lost for words, love the finish on the bogie, very impressive Laughing
  QR-INTERAIL Deputy Commissioner

Location: Where else, but Queensland
That's f#@king awesome! Shocked8)

I know where there is a little loco that could pull that wagon!!!!Wink
  WUISKE Assistant Commissioner

G'day All,
To answer a few questions, the paint job on the Ore Wagon is the undercoat.... after SIX COATS of it!

The wagon is now almost complete, please see below for the photos. All that is required now is the decals and more clear coats to get a nice shine to it.

Cheers,
Adam



  Teditor Deputy Commissioner

Location: Toowoomba
This MANLY version, is this MANLY NSW or some new manufacturer that has snuck in?

Sure you haven't done a John Allen and shrunk everything around the wagon to give us the impression you are doing a BIG MODEL.

If these are going to be your new R-T-R project, when can we expect them and how much, I would like to do a 240 car train in Queens Park, Toowoomba.

Ted (Seriously Teditor) Freeman
  Aaron Minister for Railways

Location: University of Adelaide SA
To answer a few questions, the paint job on the Ore Wagon is the undercoat.... after SIX COATS of it!
WUISKE
Ah, six coats of undercoat, that explains it, I was going to say the printer had done real well to maintain the consistent colouring and finish over a two week print.
  linton78 Train Controller

Location: South Coast NSW
Wow, that is impressive. 3D printing sure is becoming more affordable and practical. When I was working at a Flight Test Unit, while in the Navy we had an early 3D printer. To print something this size would have cost an absolute fortune! Not to mention it would have fallen apart eventually.

Adam, just how large is the printer that created these models? I presume you mean these have been produced in basically one part?

Linton
  David Peters Dr Beeching

Location: "With Hey Boy".
Nice work there Adam, but does Jade know that you put the little ones bath on wheels. LaughingLaughing
  Hendo Deputy Commissioner

So that is what the new tub for the old Robe line looks like, Rio must have paid a moxxa for that! Would love to see it with a similarly scaled AC4400DCi in their attractive silver and red band scheme. Adam, I hope you managed to get hold of the drawings as well.


Cheers,
Hendo
  KRviator Moderator

Location: Up the front
So what's one of these going to set you back?
  WUISKE Assistant Commissioner

G'day All,
In answer to a few questions,
So far as what Linton78 has said about affordability... um Mate, there is $22,000.00 worth of material in this wagon! The cost of this is only so "cheap" due to the fact that the manufacturers own two printers and are printing them in their own factory.

Aaron, if you look along the inside of the body, you will see a join line. This is where the printer lost power. Apparently there was a momentary "blip" between when the power dropped out and the back up gen set kicked in and it reset the machine. The issue with this is that due to the instability of the material during the printing process, the top of the wagon had flared out and essentially grown by about 1.5mm all round. The top section which was printed separately was not affected and is the correct size. If we had more time for this project, we would have done far more to conceal the joint.

Yes, this model was produced in one piece from the bottom up. The bogie was the same even though all components operate independently from each other, just like a real bogie.

The surface finish on the ore wagon is about twice the resolution of the bogie. The bogie was made a few years ago and had been kicking around the office for a while. We did offer to clean up the surfaces but due to the time frame of everything for this project, it was not possible. Overall though, the finish has come up rather well. Most importantly, the client is happy.

Cheers,
Adam
  raymond Deputy Commissioner

Location: Gladstone, Queensland
Hay Adam ,does the air brake work or do you put a piece of wood under the wheel(chock).

Fantasic work    


RAYMOND
  Aaron Minister for Railways

Location: University of Adelaide SA
Adam, I saw the imperfection that you're talking about, but seeing where it was in relation to exterior of the wagon (and being completely unfamiliar with the prototype) I assumed it was an artefact that was meant to be. So that's what a power failure in a 3D print looks like? Never seen that before!
  Hendo Deputy Commissioner

Adam,

Are the owners including the cost of you personally delivering it to AusRAILPLUS 2013? It would be good to see a pic of you on the trade stand with it. If not let's hope M636C gets a few pics of it on display for you.


Cheers,
Hendo
  hiddeous Junior Train Controller

Location: Brisneyland
Adam,

Are the owners including the cost of you personally delivering it to AusRAILPLUS 2013? It would be good to see a pic of you on the trade stand with it. If not let's hope M636C gets a few pics of it on display for you.


Cheers,
Hendo
Hendo
Yes Adam, are they???? would be good to see you there for a coffee and chin wag.
Pete
  WUISKE Assistant Commissioner

G'day guys,
No I am (thankfully) not delivering the models. The Ore wagon and bogie was picked up on Friday along with two narrow gauge bogies and to standard gauge bogies for the wagons that were dropped off to us on Friday. See below for the photos of those...

NHIH coal hopper... half of it anyway. The second half is still printing and should be complete within a fortnight.




CBH grain hopper. This model is around 1.6 metres long. It was printed in two halves and the power failed half way through printing one half as you may be able to see in the photos by the horizontal joint. The options for us to join the two halves together were not great and neither Jade or I are happy with it as over time it will more than likely fail. After Ausrail is out of the way, we will most likely get this model back to rethink the jointing idea they had.







  WUISKE Assistant Commissioner

Oops, my mistake on the dimensions, I have just measured the grain hopper. It is 1430mm long, 390mm high and 300mm wide... But it is a narrow gauge wagon so that explains the small size. The coal hopper is somewhat larger.

Cheers,
Adam
  QR-INTERAIL Deputy Commissioner

Location: Where else, but Queensland
Adam, out of curiosity, how robust are these models? Are they fragile?

Also, how heavy are the bogies on their own, and the say the overall weight of the grain wagon?

Again, well done on the top work.
  WUISKE Assistant Commissioner

That's f#@king awesome! Shocked8)

I know where there is a little loco that could pull that wagon!!!!Wink
QR-INTERAIL

Mate, the bogies are about 200 grams each. The ore wagon weighed about 8 kilos, the grain hopper was about 9 kilos and the (half) coal hopper weighs in at about 4 kilos. Those weights are without bogies for the coal and grain wagons. I am keen to see some photos from Ausrail as to how they actually look once on bogies as due to the extremely tight schedule, we handed bits back as soon as they were finished or as the guys from the company came out to inspect/drop off things.

I can now say that as of about 8 minutes ago, both of these wagons are now 100% complete. So perfectly timed for the pick up in the morning.

Cheers,
Adam
  Piston Train Controller

An interesting new code on the grain wagon CBHN.

To comply with the RoA coding the second letter B identifies the wagon as a box car type such as a WBAX, NBJX, or RBFX.

Grain wagons were allocated the second letter as 'G' such as MGFH, NGTY, XGAY.

The last letter was to describe the bogie type. This is the first wagon I have heard of with a 'N' classification.

Whats the use of setting up a standard code if the operators just do their own  thing?
  qredge Deputy Commissioner

Location: Marsden Qld
I assume from Adams notes that this is a narrow gauge grain wagon and as such ROA codings  don't apply ie as QR does on the 3'6"  VAKG Is the grain wagon although we tried to follow the process for a few years with QGX QLX and QFX but on Standard gauge we have ROA codings even on wagons transferred across.
  Aaron Minister for Railways

Location: University of Adelaide SA
An interesting new code on the grain wagon CBHN.
"Piston"
Cereal, Bulk Handling, Narrow.
  Piston Train Controller

Cereal, Bulk Handling, Narrow.
Aaron
Thanks for the explanation. I suppose it was expecting too much for the "narrow gauge" fraternity to follow a logical coding system.

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