CAV HQ

From CAD to CAV

Introduction

When we began the CAV project one of our primary goals was to create the highest quality white metal mecha models ever produced.

For years white metal mecha master models were sculpted by hand. Our early prototype CAVs were made using this same proven method. We attempted to upgrade this process using photo-etched parts and plastic, but the final results were still unsatisfactory.

At the same time we were creating hand made mecha master models to start the CAV project with, we also began exploring the emerging technologies of rapid prototyping. Several experiments with both CAD software programs and various rapid model prototyping outputs were conducted until we finally settled on a combination that produces, in our opinion, the highest quality mecha models ever produced.

In summary, a model is constructed on the computer. The computer design is printed on a plastic/wax 3d printer. The plastic/wax master model is converted into silver. The silver master model is used to make production masters.

1. Hand Made CAV

Fig 1a. Some CAV components made using Blue/Green epoxy and plastic.

Fig 1b. An early prototype CAV made with white metal and brown epoxy.

2. Early 3D Modeling

Fig 2. An early, and very costly, attempt to create a CAV using CAD and a laser model builder. Not only did it lack detail but note the "strata" lines present which can be clearly seen in the shoulder missile packs.

3. Panther CAD

Fig 3. A finished CAD CAV model as it appears on the computer screen.

4. 3D Print Masters


Figs 4a & 4b. Finished output from a high resolution 3d plastic/wax printer. This is how CAVs appear before they are converted to silver.

5. 3D to Silver

Fig 5. Before going into production a printed 3d model must be converted into silver. The Scorpion CAV chassis and main gun are pictured above.

6. Comparisons


Figs 5a & b. The white and red Dictator is the handmade model, and the silver and red Dictator is the CAD model.