3d Printing / Rapid Prototyping
Depending on the project requirements, Hot Buttered Elves utilizes a number of rapid prototyping methods and machines. This is a matter of finding the “right tool for the job.” While models and structural parts require strength, characters and small ergonomic parts require high detail. Some parts must be printed in clear, and others will take paint. One project may require a combination of different rapid prototype methods to resolve a solution. We print in many different materials, such as:
POLYJET
The 3D printer jets and instantly UV-cures tiny droplets of liquid photopolymer. Fine layers accumulate on the build tray, and quickly build into precise 3D shapes. Where overhangs, undercuts, or complex shapes require support, the 3D printer jets a removable gel-like support material. (Durable functioning parts with excellent detail)
SLA
The SLA process is performed in vat of liquid photopolymer resin where an ultraviolet laser is projected into the resin vat. The UV laser solidifies where it is projected, and it moves to follow the pattern, solidifying layer by layer to create or “print” a solid 3D model. Typical SLA Standard tolerances are ± .015? or ± .002?. Along with Polyjet, these are of the most accurate tolerances on the market today. (Medium Strong Parts with medium detail).
SLS
SLS involves the use of a high power laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal, ceramic, or glass powders into a mass that has a desired three-dimensional shape. The laser cures each layer in the vat, then the powder bed is lowered by one layer thickness, a new layer of material is smoothed over the top, and the process is repeated until the part is completed. (Very strong parts with medium detail).
FDM
Fused Deposition Modeling – Engineering grade thermoplastics are extruded from the bottom to top of the part, layer by layer until the part is complete. These materials are already production grade, so they have the chemical and mechanical strengths that allow parts to be physically put to the test. While the aesthetic details are not as clean as the Polyjet process, these parts are much stronger, and are used to create parts that require physical strength. (Very strong parts with medium detail).
DMLS
Direct Metal Laser Sintering – Metal parts are created in the additive manufacturing style where the laser beam melts the powdered metal composite together layer by layer. These parts have great strength, and are very accurate. The parts demonstrate the properties of metal parts, however not as strong as CNC cut metal parts. (Extremely strong parts with poor detail).
CLICK FOR SLIDESHOW
PAINTING
When your parts are printed and assembled, painting them is the next step. The Elf Workshop is designed around the Pantone color system, and has been painting and matching colors for over 25 years. If you spend the time building something great, then the final painting application must be professionally done to achieve perfection. The Elves are masters of painting, and meet all of the expectations for licensed color-matched approvals. Our paints range from Acrylics to Automotive.
3D SCANNING
3D digital scanning is an effective way to capture 3D digital data from existing prototypes or models. Products that need re-designing, re-sizing, or improvement can be scanned into the computer for further modeling. Once scanned, the models can be re-engineered to meet the required specifications. Once the changes are implemented, the model can be printed at any size.
PACKAGING
Our packaging designers work in close proximity of the product designers to create a package that tells the right story for your product. We focus on both the allowable plan-a-gram footprint, and the sustainable footprint, and work closely with the licensor assets to create packaging that makes your product “POP” on the shelves. HBE coordinates full package die lines, artwork, blisters, and tooling materials to coordinate the production of your packaging materials both domestically and overseas.
MOLDING/CASTING
Our molding facility has been built with years of experience. We have designed our own machines to adopt our special method of molding and casting parts. We work with the most advanced silicones and molding techniques, and have been teaching them for years in the Toy Design Program at Otis College of Art and Design in Los Angeles. Pressure and vacuum environments are used to control materials and eliminate defects. Multiple cavity molds are designed to control undercuts and achieve perfect reproductions.
ELECTROPLATING
Gold, silver, chrome, and copper are electroplated over plastic and metal parts. This process is common when making awards or statues that need to have that “Academy Award” finish. Real 24 carat gold.
LASER CUTTING
2-Dimensional laser cutting is an excellent way to create gears, lettering, signage, and create model parts with accuracy and precision. Illustrator files can be imported to cut your patterns out of wood, acrylic, and metal in thicknesses up to 3/4 inch thick.
VACUUM FORMING
We are capable of vacuum forming a wide range of shapes. Models are created either digitally or by hand, then are modified and set up for vacuum forming. We can work with large 4 x 4 foot and 4 x 8 foot models and vacuum form over large foam sculpted characters, or can arrange for blister packaging. We support many different materials from PETG, ABS to Acrylic and styrene.
PLUSH
Starting with the 2D design, our experienced pattern designers create a 3D plush white model for size and pattern evaluation. Then the correct fabrics are isolated, and the final plush is created. HBE can engineer internal mechanisms, gears, and housings to support movement or character action per your imagination and budget. Overseas sourcing is available for plush programs.
