DORA

DORA the EXPLORER

PURPOSE OF THE PROJECT - Creation of a prototype of a thermoformed package design that incorporates “relief-sculpted” character likenesses. The final manufactured piece is intended to serve both as packaging for the product (art supplies) as well as a carrying case. The two characters featured are from Nickelodean’s cartoon series, “DORA the EXPLORER”. At the point that this project was sent to me, two separate engineering firms (one domestic & one in Asia) had failed in their attempts to produce digital models that Nickelodean would accept. This was due to both firms attempting to execute this type of a project solely within mainstream CAD modeling programs. This project stands as a classic example of how Freeform can provide the modeler with tools and capabilities that no one else can!

CLIENT - THE HOLLOWAY GROUP INC.

PROJECT DATE - August, 2006

PROGRAMS USED - FREEFORM V-9 / ARTCAM PRO


				This project begins with the client supplying a line art “control drawing” of what was wanted.




		Working from the “control drawing”, the individual figures were “roughed out” with the primary emphasis focused on establishing proportional relationships amongst the major shapes.


	After final approval is received regarding the accuracy of the likeness to the character, the model is compressed along the “Z” axis to meet the dimensional specifications for the relief height. This is accomplished using Freeform’s “deform box”.




	The completed characters are now test fitted to the front case. Small details (created in Artcam Pro) are added to the handle.


The final adjustments are made and the characters are merged with the case and blended in.




		Due to the design and the means by which the two halves of the finished case were intended to fit together, modeling the back half of the case proved to be somewhat challenging. The first step required is that the front half of the model be “shelled” to a wall thickness of .030”.


	The first objective of this project was to generate digital models of the front and the back of the case itself. The second objective was to use those models to create mold cavities that could be “printed” using a Z-Corp 3D printer. These mold cavities were then to serve as temporary tooling for generating actual vacuum-formed prototypes. The mold cavity for the front half of the case was created by using the model to subtract material from the mold block.


	Modeling the back half of the case was then accomplished by performing a series of “offsets” & subtraction procedures.


	The cavity for the back half of the finished case.