Evolution Product Design

Composites design is predominately recognised as the technical process where a team of engineers and project managers collaborate to develop a composite part. They focus on material properties and weight saving ratios, and combine this with other factors like aerodynamics and mechanics.

However, an opportunity exists, particularly in the automotive / heavy vehicle industry, to experiment and design with alternative thinking and processes. This is the role that Evolution Design strives to fill.

 

Zbrush is a 3D modelling / sculpting software developed by Pixologic, often used for character, and jewellery design. As an alternative to other engineering based software like SolidWorks and Autodesk Fusion, ZBrush and  is used to 3D model and sculp a custom – composite part. The part shape is sculpted using a Wacom Cintiq and pen.

 

Cinema 4D and Octane render is used to visually simulate the end aesthetics of this project. By creating UV mapping inside Cinema 4D, the carbon fibre material displays an accurate example of the intended finish for the final artifact.

In addition to this, the chevron join is also created by splitting the object in half and mirroring at centre. The UV map is then oriented +-45 degrees to display the effect. To compose an animation with renders, Adobe After Effects is used to compile the footage into a sequenced, editable format.

4 axis – CNC machining is used to accurately cut the polystyrene  blank. The advantage to using Zbrush, is the high polygon mesh created produce very clean surface finishes requiring mininmal preparartion prior to laminating.

Expanded polystyrene makes the perfect blank material, as it is a cheap stock material and requires a epoxy resin coat, suitable for carbon fibre and other high performance fabrics.

Another advantage with polystyrene, if the blank is to be sacrificied, acetone will melt the core material effectively leaving a composite shell, or 100% fibreglass, carbon fibre, kevlar – composite part.