Physics Trophy from Sketch to Physical Product!
Most of the time I design directly from something that I have planned in my head but for the recent trophy, I had to do a few sketches to mesh-out some ideas. Sketching is quicker than building the model in 3D and helps to see what’s possible and what isn’t in very short order.
My first idea was to make a general “sciences” themed trophy, as you can see from this sketch, it would have been far more ambitious than what I ended-up with.
First sketch of the Science Trophy
As you can see, the trophy was going to be really 3D with large parts extending from all sides at all angles. I envisioned it being about a meter tall using 6mm plywood so that I’d have enough resolution to make a decent enough solar system and flying saucer above. This was for Trotec’s tradeshow and as a result, I had to abandon this idea (for now) because it would be too unstable and easy to break traveling all over the place. I also had a very real fear of it tipping over too easily. It would have to be carefully balanced. I also had to keep the parts count as low as possible for quick assembly – this model would have easily surpassed a hundred pieces as I wanted the planets to be able to move and the flying saucer capable of rotating.
Science Trophy Sketch 2: simplifying a design
Alright, I went a bit extreme to see what elements I could remove from the design while still keeping to my original idea. The original trophy was designed to be viewable from all around but was too unstable, I really wanted a flying saucer in the design but in the end, I had to drop it. The fear of easy breakage mixed with tipping over was too big. I decided to focus instead of sciences in general – on just the theme of physics so you have nuclear energy, possible due to Einstein’s theories with the number one in the middle.
Physics Trophy: Design Evolution (720HD)
As you can see from the evolution of design video, the model was rather straight forward once the ideas were in place.
Final Trophy Design
Once the assembly animation was completed, I knew the design would fit together perfectly – again, I only use the amount of material removed by the laser as my tolerance for all the intersecting parts.
Physics Trophy: 3D Assembly Animation (720HD)
The next step was making the EPS/DXF/AI/PDF files for the trophy. I usually make the PDF instructions first because it’s another way to test the model to make sure everything fits properly. If the animation works fine without any issues and the PDF goes as smoothly, then the DXF/EPS works fine. I then sent it off to David Newman who expressed interest in cutting it for me on Trotec’s behalf and here was the result.
David Newman from Blue Tongue Engraving
So here you go, from initial brainstorm sketch to finished product!