Foam Models

Packaging Components

Squeeze a round peg into a square hole? It can be done! We just need to figure out how. Creating volume studies support the design process and influence the overall ergonomics and form. Fitting multiple components into a small work envelope is always a challenge. We create volume studies early on and throughout the entire development process so we can address these critical areas before they become an issue for prototyping and/or manufacturing.

Volume studies are great learning tools for populating internal components to test clearance issues, engineered housings, and are a great initial QC [Quality Control] tool during early development. Volume studies are also utilized in consumer research, where mono-chromatic volumes are studied, presented to consumer, and designed within parameters prescribed by the feedback from the potential consumer.

Volumetric Models Support:

Ergonomic evaluation
Overall product envelope investigation
Consumer research evaluation
Contextual analysis (comparative research)
Color schemes
Interference detection

Case Study: Tennant

Tennant is a manufacturer for floor scrubbing machines in the commercial industry. Though their products are relatively large, quite a few components still need to fit in the work envelope. We CNC machined a series of large [approximately 48” x 60” x 36”] Volume Studies out of low-density urethane foams and laser carved SLA’s that allowed their engineers to strategically locate parts and pieces within the machine, in a timely manner. Not only used for an internal component exploration, the volume study was also painted to formulate color schemes and textures to simulate the overall production outcome. Tennant developed a rolling chassis concurrently at their facility, while we were fabricating the shell here. When we mated the two, it fit-up without a flaw. We even rode it around the office!