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Stonehenge replica

The Stonehenge stone circle is the most famous Stone Age monument in Europe and is a UNESCO World Heritage Site. For a special exhibition of the LWL Museum of Archaeology in Herne, a full-scale Stonehenge replica as naturalistic as possible was to be produced as a monument that can be walked on and touched. We participated in the tender for this gigantic project and finally received the order. A total of 21 Stonehenge replicas on a scale of 1:1 were ordered, ranging in height from 4 to 7 m and up to 5 m wide.

Gigantic tasks

This literally gigantic order also presented us with some technical, time and logistical challenges. The 3D data of the giant stones provided by the customer first had to be divided into feasible sections. The individual elements were CNC milled from Styrofoam. Then, the large elements were merged together to form the stone replicas on a 1:1 scale.

The next step was to achieve the most realistic-looking surface possible for the stone giants. First, the “soft” Styrofoam was coated with a layer of polyurea hotcoat. This plastic coating significantly increased the compressive strength of the surface. The basis for the further coloration was then formed by freshly processed sarsen or bluestone optics. On the basis of photographic material and small original samples from Stonehenge, various types of sand were matched to each other and a suitable mixing ratio was determined. Because the replica stones should also
haptically resemble sandstone, the special sand mixture was sprayed onto the stone surface in combination with a dispersion adhesive. The details of the stone surface, as well as the color nuances, were finally worked out by airbrush painting.

Due to the large dimensions, the stones had to be precisely divided again for transport and assembly. The last hurdle was the assembly of the stones on site at the LWL Museum of Archaeology Herne. This was done by our team over two days. The huge stone models had to be assembled like a puzzle with the help of several scissor lifts and fixed to a substructure. The seams at the connection points were reworked by us after the assembly.

The impressive special exhibition about Stonehenge in the LWL Museum of Archaeology in Herne was opened on 23.09.21 and can be seen until 25.09.22.

Bilder aus der Produktion:

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GIANT HANDS FOR IAA-Fair

At the internationally important IAA automotive trade fair in Frankfurt 2019, AUDI has presented its new convertible model in a particularly eye-catching way: the Audi A5 40 TDI quattro is staged by two white giant hands. This staging makes the trade fair stand a special eye-catcher, to which we were allowed to make our contribution.

By order of the company Metron eging GmbH we made the two over 5m large hands out of FRP.
First, the oversized hands were milled from Styrofoam on a five-axis CNC machining center using the CAD files supplied. To obtain a hard surface, the Styrofoam models were coated with a 3 mm thick layer of FRP using the hand laminate process. To keep the oversized hands as light as possible, the entire Styrofoam was then removed from the inside.


To create a smooth and even surface, the entire area had to be filled, sanded, filled, sanded and primed. This was followed by a white matte paint finish. Good cooperation with the customer ensured trouble-free assembly to the customer’s framework.

Bilder aus der Fertigung:

 

Gigantic figure


By order of 3D Culture we were allowed to produce an imposing, 4 meter high figure. First, individual body parts were milled from polystyrene using CNC machining centers.

Since the figure was later to be given an illuminated arm by the customer, cable ducts for the electrical installation had to be taken into account.

The milled individual parts were glued together and the surface was given an initial sealant. Thus, the giant was ready to be sheathed in FRP. After the finishing work on the surface, it was painted uniformly in white according to the customer’s wishes.

The impressive giant then cut an undoubtedly fine figure at the trade show for five days.

 

Pictures from the production line:

 

Dental implant illustration model

Anschauungsmodell Zahnimplantat

This 2m high display model represents a multiple enlargement of a dental implant. It is used for illustration purposes at trade fairs and exhibitions in the dental field. The data supplied by the customer was prepared by ACCENTFORM in CAD/CAM programs.

The individual parts were manufactured and assembled using our CNC milling machines. The B1 classification had to be taken into account. The styrofoam model was then encased in FRP and smoothed.

The smoothing of the surface is a very complex process, here the surface is sanded 3x, 2x filled, so that the final finish paint can be executed in a high surface quality.

The surface painting was done in a noble titanium look, true to the original – smooth on top and provided with a rough surface in the lower area of the implant.

To ensure stability, the model has received a steel plate in the base area.

Pictures from the production:

Floating faucet

Faszinierende Illusion – ein Blickfang für die Besucher

The principal of the “floating faucet” is based on an optical illusion. In a transparent tube, water is pumped into the faucet. The water flows and then, falls back down on the outside of the clear tube. Because the transparent tube with the water intake cannot be reflected in the “waterfall”, the impression is created that the water comes out of nowhere.

The floating faucet is an eye catcher for waterworks and gas- and water installation companies. The coated item costs 6800€ plus value-added tax (VAT).

For the building material dealer, MeckRohr, we designed by means of CAD, an oversized fibreglass outlet valve, made of hard foam and covered with 2 mm thick fibreglass laminate. Subsequently, the outlet valve was finished with an acrylic varnish.

Den schwebenden Wasserhahn können wir in folgenden Ausführungen anbieten:

 

Wasserhahn “MODERN” für einen Messestand, im Auftrag von Firma Scarso:

Wasserhahn “ANTIKE” für den Baustoffhändler MeckRohr:

 

 

 

Huge Molecule Model

Molecule – Company Logo Replica
molekuel-Zeichnung

molekuel-gfk

Production of an oversized molecule as an eye-catching exhibition booth display.

The molecule floated at the height of 5 meters (5.5 yds.) in the center of the booth. For the production of the spheres, three were made 840 mm (33 in) in diameter and one 1200mm (47 in) in diameter, as well as three connection pieces. These orbs were formed into a molecule by means of the connection pieces. After being primed and smoothed, the surface of the molecule model was prepared for a glossy and reflective coating.

Subsequently, the molecule model was painted blue and yellow to give it a spectacular touch.

 

Diamond-Shape Artwork – Audi

Artwork for Audi at the Design Miami / 2013

The Audi exhibition stand at the Design Miami / 2013 is dedicated to the Audi Sport. Two super sports cars, well lit, were presented in front of the ACCENTform manufactured red diamond-shaped backdrop.

The artwork consisted of nearly 30 different sized diamond-shape elements, from 50 x 74 cm (19.7 x 29 in) up to 2.40 m x 2.07m (8 x 6.8 feet) in size.  These pieces, were made of a fibreglass sandwich panel in order to improve their rigidity. One diamond-shape element (sidewalls and cover) was produced by us utilizing manufacturedmolds. Then, all the produced parts were assembled and smoothed to remove all appearance of seams.

All elements were coated with a high-gloss finish in the typical Audi Sport colour- red.

The three-dimensional installation plays, in visual way, with the diamond-shape objects, the symbol of Audi Sport. These rhombi were hung on the wall, glued together to form a column, and suspended from the ceiling.

The main challenges in this project were the complexity of the shape and the surface treatment of the rhombi. All these elements were made with mirror-like surfaces.  This  called for an extremely high level of care.

We also made remarkably stable transportation racks, which were air and sea cargo worthy, to protect the sensitive surfaces during transport.

We were able to achieve the level of perfection as required by Audi.

We cooperated closely with our client and we would like to thank Expotechnik GmbH for its terrific cooperation.

 

Highlight Wall For BMW

Two Brand New BMW Cars Were Presented in Front of the Highlight Exhibition Wall

The two BMW cars “drive” between our two-part exhibitions’ highlight walls in the spotlight of the “Auto Salon” in Geneva. The highlight of this extravagant background is the 183 diamond-shape light cutouts. The wall had the shape of two spherical sections and the corresponding sphere had a diameter of 16 m (17.5 yards).

One wall section was approximately 5.3 x 12.0 m (5.8 x 13.1 yd)and consisted of six single parts linked to each other. For the production of these parts, a large production mold of approximately 2.7 x 5.0 m (3 x 5.5 yd) in size was used. For the light cutouts – 183 molds. Through an economic, efficient, and computer-aided design, efforts spent on this production were reduced to a minimum. The light molds modeling board material were made by our five-axis industrial robot.

Due to precise positioning of molds on the production form, the wall sections were made geometrically accurate. In order to increase the rigidity of the wall elements, the honeycomb-shaped bracing was installed on the back of the wall.

The collaboration with our client ensured a smooth installation on the customer’s steel frame. For the job itself, we would like to thank the company Winkels Messebau.

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Azipod® Model

THIS IS HOW CRUISE SHIPS ARE POWERED TODAY

Few people know that large cargo and cruise ships today are powered by electric motors – with the electric motor hanging directly with the ship’s propeller on a rotating bearing in a nacelle underneath the ship. Today, the well-known “ship’s diesel” only generates
the electricity required for this purpose and can now run highly efficiently and therefore much more fuel-efficiently and environmentally friendly, regardless of the ship’s speed.

These innovative electric drive systems from ABB® are called Azipod® and not only lead to a lot of advantages for the environment and economy. Thanks to the compact design, space requirements are also significantly reduced: no rigid shaft, no control system also means more space for cabs and cargo, fewer wearing parts and less vibration..

mg-2835-MGThis innovative propulsion system, which is part of the equipment of a new and “greener” cruise class, was to be impressively presented at the visitor center of MEYER WERFT in Papenburg. Therefore, ACCENTFORM received the order to build a 1:1 model of an Azipod® propulsion system – no problem for the ACCENTFORM team.

After the production molds for the nacelle and the five different blades had been prepared, the individual components were manufactured in hand laminate with a wall thickness of 5mm. A FRP hemisphere serves as the tip of the propeller. Attachments for the floor and ceiling are located on the individually removable wings. All segments were primed, the nacelle was also painted in our factory. The painting of the five blades was done by the client.

After completion of all remaining work, the propeller was assembled in Papenburg. The impressive model can now be admired in the MEYER WERFT visitor center.

Space Shuttle Rocket Engine

ACCENTform was commissioned by Creative Services KG to produce an exhibit where the visitors experience the effect of blasting off into space.  This true 1:1 fibreglass replica of a space shuttle rocket engine is displayed at the German Aerospace Centre (DLR) in Bremen. The aim was to comply with the customer’s requirement that both the insides and the outsides have an authentic-looking surface that realistically captures the look of the space shuttle main engine assembly.

The engine nozzle, made ​​by ACCENTform, was installed vertically, in the correct height of nearly 5 meters (5.5 yds.) and assembled on-site.  This was a huge challenge for all persons involved.  Thanks to the FRP material, the rocket engine had the following final specification:  2.23 meters (2.4 yds.) in diameter, 2.7 meters in height (3 yds.), was extremely light, weighing in at 100 kg (220 pounds) and also very stable. Because the access area of ​​the exhibition hall was tight and hard to access, the engine nozzle has to be divided lengthwise into four single parts that were manufactured separately and then assembled on-site to form the finished rocket engine.  Finally, the entire engine nozzle, with a total surface area of approximately 25 m² (27 yds².), was painted in matte black.

 

In order to provide visitors with a unique and tactile experience, the requisite fuel pumps were installed by the client and for added realism, an infrared heater was mounted inside the shuttle engine. To comply with existing safety regulations,  ​​ACCENTform made the fibreglass model in the fireproof design according to DIN 5510 (S4, SR2, ST2) standards. Because of the radiant heating, the visitors standing beneath the rocket engine felt an intense afterglow, while above them the imaginary space shuttle lifts off into space.