Material

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3D Printing

Rapid prototyping is used for form exploration and projects that require fast turnaround.  At Spark, we use different 3D printing technology to achieve different fidelity of prototyping that meet various needs.  SLA is often used for mid to high fidelity prototyping and objects with complex structures.  Here are some examples of our rapid prototype capabilities.

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Wood

Natural materials such as wood are used in high-fidelity prototypes to realistically represent the original design intent.  Spark uses real wood such as oak, walnut, birch with CNC machining and polishing per designer’s spec.  In some cases, hydrographic printing technology is used to simulate wood textures and patterns on plastic.  Different stains and finishing can also be selected for different types of wood.

Wooden Handle

Wooden Knob

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Silicon & Soft Plastic

Soft plastics are frequently used for touchpoints in consumer products.  Spark has the capability to mold various soft plastic materials such as silicon, polyeurethene, etc.  Common applications for soft plastics are: protective casing for consumer products, handles and various touchpoints, keyboards, packaging, etc.

Silicon Cup Holder Mat

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Transparent Plastic

Transparent plastic is often the most time consuming and labor intensive part of a model.  The quality of polishing directly affects the clarity of the plastic.  From clear refrigerator bins to clear bowl that are tinted to simulate glass, Spark takes pride in our transparent / translucent models.  We use machined acrylic and molded clear polycarbonate blend for most of our clear models.  3D Printing is also used for complex designs and shapes.  Common applications for transparent material are: See-through parts, glassware, color dyed objects, clear vessels, etc.

CNC Acrylic

Frosted Clear Plastic

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Carbon Fiber

Custom carbon fiber is used on functional prototypes and small volume production parts.  We have completed projects from bike frames to auto body parts.

  • Client: Private Client
  • Fidelity: Production 
  • Product: Car Door
  • Material: Carbon Fiber
  • Tools: CF Fabrication 
  • Time: 20 days 

Detail Images

Carbon-Fiber-Car-Door-2
Carbon-Fiber-Fender
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Metal Work

Putting the “bling” on your product is important.  Metal work is one of our core competencies at I2V.  We specialize in machining, forming as well as molding of various metals.  The metals we work with include aluminum, stainless steel, zinc as well as different metal composites.  For one-of-a-kind modeling, our metal crafters have the skills to bring a piece of metal to life, paying extra attention to detail and setting a high standard for accuracy.  The best of all, our metal work costs a lot less than most prototype house.

  • Client: NA
  • Fidelity: Production 
  • Product: Control Panel 
  • Material: Aluminum 
  • Tools: Metal Forming 
  • Time: 5 days 

Radial Brushed Knob

Machining is any of various processes in which a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. The many processes that have this common theme, controlled material removal, are today collectively known as subtractive manufacturing, in distinction from processes of controlled material addition, which are known as additive manufacturing. Exactly what the “controlled” part of the definition implies can vary, but it almost always implies the use of machine tools (in addition to just power tools and hand tools).

Metal forming, is the metalworking process of fashioning metal parts and objects through mechanical deformation; the workpiece is reshaped without adding or removing material, and its mass remains unchanged.[1] Forming operates on the materials science principle of plastic deformation, where the physical shape of a material is permanently deformed.

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