Case Study – IAVA Second Annual Heroes Gala

Process Utilize – Urethane Casting / CNC Milling

The Objective

The IAVA (Iraq and Afghanistan Veterans of America) approached use to produce clear acrylic awards for their upcoming gala in New York City. Their goal was create a country which honors and cares for its newest generation of veterans and their families.

The Challenges

The awards banquet was less than a week away and they needed 6 flawless awards to present at the event. The awards consisted of a Clear Acrylic Body and solid gold custom nameplates that were to set in the base of the award.

The Solution

The CAD file for the Award Body and Gold Plaque was used as used to produce a high resolution STL file to be grown on a SLA Viper and milled out of wax on a CNC Machine, respective.

Utilizing the native CAD data an IGES file was created to be used with the CNC Equipment. The file was imported in to the machines platform and the tool paths were generated. The mater pattern was then cut from wax using CNC cutters as small as 0.003” at the tip.

The mater pattern was then cleaned up and sent to a casting house to be cast in 24K gold.

 The Award Body file contained features and details that had to grown perfectly. The file was pre processed using the equipments proprietary software to generate the build platform. Custom build structures as well and recoating pattern and applied then to the critical areas on the award. The fine features and details grew without a flaw. The part was then sent to the casting department to be finished as a RTV Mold Master Pattern. The mold was produced and cut then the awards cast. The awards were completed and delivered to meet the tight deadline. The picture to the left shows Arnold Fisher receiving his customer manufactured Civilian Service Award just 5 days after the design was completed.