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BLOCK MODELLING
WITH LIGHTWEIGHT POLYURETHANE MODEL BOARD EMPLATE
V.Ryan © 2015
 
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The design of a small handheld device is shown opposite.

Describe how it could be ‘block’ modelled’, as the next stage of the design process.

   
 
 
SELECTED MATERIAL: Low Density Polyurethane Model Board
 
 
MATERIAL PROPERTIES: Lightweight polyurethane model board, is ideal for cutting and shaping by hand. It has a smoother surface finish than styrofoam as its granular form is finer. It can be shaped quickly using basic hand tools or even machines. It is supplied in a range of sizes and thicknesses.
 
A block of low density polyurethane model board is cut to a suitable size, using hand tools (coping saw) or a fretsaw.
   
The outer shape of the model is cut using a fretsaw or hot wire cutter. Care is required because polyurethane model board cuts very easily. Cut very slowly, as the material offers very little resistance.
 
 
 
The outer shape is carefully filed, to remove rough edges and to ‘round’ corners.
 
 
Use wet and dry to smooth the edges, ready for painting.
 
 
Using acrylic / water based paint, add the detail to the polyurethane model board.
 
 
 
 
The add a printout of a speaker and glue in position with PVA.
 
 
 
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