Columbia University FSAE Team Car

Again another really fun project with our friends at the Columbia University FSAE team.  What an impressive group of students! Check out their site here.

We worked with the team engineers to create the molds for the cars body out of Precision Board HDU.  The team then molded the carbon fiber panels.  Once completed they sent us the panels for final finishing where our guys wrapped all of the parts in a black brushed metal vinyl.  All of the logo and number decals were then created and installed.

It really turned out great -Congratulations to the 2016 team and best of luck!

Oh and thanks for the tie!

– Steve

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Wright Family Farm Sign

We were very excited about this sign. Our friends at the Wright Family Farm in Warwick, NY needed to replace an old sign on the main road in front of the farm. This farm has been around for over 100 years so we felt very privileged to be involved.

So we stepped in to help with the task by creating a new design that would incorporate everything they had to offer. Nanette jumped on the design and came up with a wonderful sign design that everyone was extremely happy with.  Now we have to make it….

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We had to come up with a way to get the background detail in while keeping the sign dimensional. It was very important to make it really stand out for people driving by. We decided to UV print the details of the back to dibond then mount dimensional letters to the face.

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Peter takes the 2D artwork and converts to 3D in Enroute Pro. Then we are ready to carve the rest of the sign in two parts. we then glue them together with the hangers installed.

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Off to the paint room where Holin will paint the sign with a  latex a enamel.

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A little bit of assembly and we’re ready to deliver.

Best of Luck with your new sign!

– Steve

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Adding a little character to a sign

When working on larger projects it’s the little details that really make the difference for both the client and for us! Our current project is no different. We are creating a “themed” environment for the Fox Island Creamery & Café in Hewitt, NJ.  We’ve  created a nice little storyline and have developed some characters which should make the experience fun for both the kids and parents.

This sign is for a little beaver character that we created and his boat company. The Chubby Beaver Boat Building Co.

We started with a rough sketch, now I knew we would need a boat, a beaver and the back of the sign. So we started there.

Peter worked directly in Enroute Pro to create the shape and used some fun font styles for the carvings. We carved the sign out of 15# Precision Board HDU on our MultiCam 3000 CNC. Once the CNC was done with it’s job Peter hand carved the edges for the “beaver got to it” texture.

 

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We sealed the foam with Aqua Resin, then primed and spray painted our base coat.

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Using latex paint we painted two coats of a darker glaze to get a nice aged look on the wood.086090

Now are sign back is complete and its time to move on to our beaver!

I’ll carve the basics out of 15# Precison Board so I used Mudbox 3D Software to create the body and facial structure of the beaver. Once carved I used Magic Sculpt for the details.

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Hmm, I think my little guy could use some glasses. I’ll use the 3D printer for this little detail. I printed  2 pairs different sizes, the larger ones look best.

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We most definitely need a boat for this sign. This is a perfect task for our 3D Printer as well. I found a basic 3D boat online – downloaded the file and sized it perfectly to fit our beaver. 4 hours later we had our 3D printed boat. I love technology!

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A few more details and paint and we are all done – Can’t wait to hang it!

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bfree Sign: A Dimensional Sign of Metal and Wood (or maybe not)

I am lucky enough to live in the great town of Warwick, NY – we have wonderful restaurants and shops and its a destination for many people on weekend getaways. There is a new trendy shop opening, bfree and we were lucky enough to be called to help with her “new” look.

The clients logo needed some tweaking and unfortunately wouldn’t work on the sign.  We started by taking the logo and reformatting it to match the “feel” of the store and to better represent what you would see inside.

Our graphic designer Nanette jumped in and began creating a new logo which would incorporate wood, brushed metal and copper.

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Client loved it – now its time to make this baby!

We began with 15# Precisionboard HDU at a 1.5″ thickness. This will allow us to get all the elements, except the bfree letters on one panel.  We carved the brushed texture and branch into the background and the wood texture of the frame using our MultiCam 3000 CNC.

595 599We drilled holes and cut pockets for our lettering which we’ll make separately as a two part letter.  605 While the machine was working away Peter experimented with the some techniques to create a realistic copper finish.

603We’ve sealed the foam with a coat of AquaResin and and primed. ready for paint!

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We are using Modern Masters metallic silver as the base coat for the brushed metal. we’ll then add several glaze coats of latex color over it. When the sun hits it during the day it will shine like real metal and at night the overhead goosenecks will really bring out the metal finish and texture.

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While Peter is painting the silver Holin is in the paint booth painting the letters. We’ve carved the copper “swirl”  texture directly into the PVC cut letters for additional texture. We’ll then mount the 1/4″ Copper PVC textured face to 1/2″ black PVC for dimension and to also add some contrast.

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017 018 023 024 The letters are done – we’ll take them off and focus on the wood frame.

The latex base coat of the wood frame goes down then two or three coats of darker glaze. We now have a nice contrast of colors against the copper and black letters.

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All painted – ready to go on the truck for the install.

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171Installed and lit and looks great! We wish bfree the best of luck with your new location.

-Steve

Custom Logo Sign

Oh how we love our friends at Jura! Not only are they wonderful people but they make the greatest coffee makers on the planet!

As they are building out their new headquarters they requested KDF to fabricate a large logo for the reception area.This logo is approximately 4’x8′.

We are making it out of 1 piece of 15# Precision Board HDU which is 2″ thick. We remove excess material from the back to reduce the weight. Once complete we’ll pin mount it to the wall.

After cutting the logo we spray a coating of AquaResin to give it a nice hard shell and to seal the foam. A quick sanding and we have the finish we need for painting.

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Two coats our PPG waterborne primer.

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And then color….

110  Once the color has dried we applied a satin clear coat.103  And we are ready to install!

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All done. Best of luck in your new headquarters!

(I need to go get some coffee)

-Steve

 

 

Full 3D Dolphin Art Piece

We recently had a great opportunity to work with an artist client of ours.  His piece incorporated a  five foot long three dimensional dolphin. Of course we immediately said yes to the project and jumped right in.

We started by sourcing a 3D Model of the “perfect dolphin” for the job – the client reviewed all the options and once he settled on the final shape we began our work.

In the 3D model we removed the fins which will be cut separately and attached later.

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From the 3D model we created a relief for each slice, 2 slices per side. Our material will be 4″ thick 15lb Precision Board HDU. All of the design work  was done directly in Enroute Pro. 119

Now we’re ready to start cutting the HDU on our MultiCAM 3000 CNC. We start with a long 1/2″ Foam Bit on the rough pass to remove the excess material quickly.  Then move to a 3/8″ Ball End Mill for the finish pass.

123 137 152 156Once it’s all glued together we’ll sand the facets off for a smooth surface.

Now its time for the fins!

To cut the fins we decided to cut each fin out of 1 piece of foam. So we cut the first side – then reregistered the foam block on the table and cut the second side – giving us a seamless 3D part.

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Now its time to send all of these parts to the paint shop for some steel, finishing and painting.

Fist the steel frame needs to be welded and set inside the dolphin. This will give the piece a lot of strength and we can hide the support bracket that will bolt to the steel stand. photo

photo 1Once the welded frame is complete the dolphin can be screwed and glued together. Then the first coat of primer is sprayed.photo 5

All the holes will get filed and the crew will sand and sand and sand until perfect. The final paint and clear coats applied and the finish will look like glass. Here is the dolphin in all its glory at the gallery in Germany.

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Fizzy Lifting Soda Pop Candy Shop Sign – Part 4

All done and ready to install.  What a fun sign to make – We hope this draws in people from far and wide to stop into this great shop. photo 1 John is on the street! After shoring up the existing sign bracket and doing some spot painting on the new steel he’s ready to hang the sign.139 142 146 All done!
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Good Luck Adam and the gang – We wish you the best with the new store!

Oh and can you stock Reggie Bars?

 

Fizzy Lifting Soda Pop Candy Shop Sign – Part 3

We are getting close. Brian’s been welding, building and painting away. Now that he has all the letters done he’s moved on to the sign faces. these will be a bright red and will really stand out at this little corner shop.

He started by welding the inside frame of the sign.  This will make it incredibly strong.

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IMG_4104Now back to the sign faces. Using our Matthews Paint system Brian matches the clients red and preps the paint guns. IMG_4107Several coats of color are put down to get a real nice, and strong, finish.

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Ready to clear coat and assemble!

 

 

Fizzy Lifting Soda Pop Candy Shop Sign – Part 2

We’re ready for paint.

Its time for Brian to work his magic. He’ll start with the letters then set them aside once complete to work on the sign panels.photo 1Once the letters are primed he lays down the PMS matched color. He’s using a Matthews Paint System.

photo 3 Using an airbrush technique, Brian lowers the pressure on the gun to stipple paint the letters to match the logo design.photo 6Here is the final logo before we attach it to the sign face.photo 7

Fizzy Lifting Soda Pop Candy Shop Sign – Part 1

Some jobs are fun from the beginning to end. My family and I were recently at a great new candy store that opened up in our town – Fizzy Lifting Soda Pop Candy Shop.  The store is as great as the name and if you’re ever in Warwick, NY you have to stop in – they have every candy you can imagine and more.

We had a nice conversation with the owner and wished him luck then he mentioned he was in need of a sign – so we sprung into action.  They have such a great logo, a bottle cap and a fun font. I told him I’d love to take on the project.

So here is where we began – a very nice logo just screaming to be produced as a dimensional sign.

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We got started right away using Enroute Pro software to  create the dimensional sign. the overall dimension will be 42″ round. The Sign will be double sided and hang on a nice scroll sign bracket off the front of the building.

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Once the 3D logo was completed. It was time to start cutting. We started by cutting the details of the sign face out of 1″ and 1/2″ White PVC.732731We are using 15lb – 2″ Precision Bard HDU for each sign face with a 1″ layer for our inside frame.   791

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Everything is now cut and ready for assembly!