Wargames Factory Implements SensAble FreeForm 3D Modeling
 WOBURN,
MA, Oct 22, 2008 - SensAble Technologies, Inc, a leading provider of
3D modeling solutions and haptic devices, announced that its
customer, Wargames Factory, maker of highly detailed miniature
figures for wargamers and collectors, has used SensAble’s FreeForm
3D modeling system to create two new figure sets, debuting today,
with time- and cost-savings that typify the competitive edge
available from today’s all-digital processes.
Using the FreeForm 3D Modeling System as the centerpiece of its
product design and prep for manufacturing process, Wargames Factory
shaved 40 percent -- more than a month -- off the time needed to
create and produce its “Caesar's Legions” (Late Republican Romans)
and “British Zulu War Infantry” figure sets. The company lowered the
cost of creating the manufacturing molds for multi-part figurines by
nearly 20 percent, while achieving greater precision with the
modeled figures.
Wargames Factory, which is based outside Boston, has just 6
employees and embraces a variety of innovative business practices
such as using recycled plastics in its miniatures, employing people
with disabilities for production through a partnership with
Triangle, Inc, and streamlined design-for-manufacturability
techniques. Founder Tony Reidy launched Wargames Factory a year ago
with a huge passion for historical gaming, a vision for improved
design and manufacturing processes – but only a small amount of
investment capital.
To reach the estimated 4 million hobbyists worldwide with a zeal
for constructing and painting 28mm miniatures and recreating
historic battles with their friends, Reidy realized he needed
exceptional detail in the costumes, poses, and facial expressions of
his miniatures – producing them at smaller volumes than larger
firms, and yet still meeting price points starting as low as $14.95
per set.
“Despite the talk about all-digital manufacturing, an amazing
amount of the plastic-injection molding business still uses
labor-intensive, manual processes,” Reidy said. “It is very much an
art more than a science.” Many toys and models are still hand
sculpted in wax or clay with injection tools made using a
pantography process where the parts are traced over to produce a
scaled version prior to cavities being cut into the steel – a stage
where many manual processes are needed to create the final mold.
This traditional process can take up to 20 or more weeks from start
to finish for highly detailed parts such as those created by
Wargames Factory. Even when executed by experienced workers,
pantography can lead to areas of lost detail on parts and
manufacturing problems that can halt production.
To achieve the goals of the business plan, Wargames Factory knew
that the ability to quickly produce new box sets would be key -- and
would only be possible through all-digital efficiencies.
“After looking at many alternatives, we determined that FreeForm
was the only software available that would allow us to design our
miniatures for precision injection mold tooling and manufacturing –
letting us create highly intricate sculptures that preserve their
detail, in record time,” stated Reidy. “In addition to saving time
and costs, FreeForm allowed us to have confidence in the parts that
we deliver for tool design. The beauty of FreeForm is that we know
that what we put into the digital process is exactly what we'll get
out of the final mold.”
FreeForm is used by product designers in many fields because it
is tailored for creating curved, organic and non-geometric shapes,
such as collectible figurines. Instead of working with a computer
mouse, FreeForm users hold a stylus-like PHANTOM haptic device, and
literally sculpt by touch – actually “feeling” the figurine’s
surface as they are designing on-screen – just as they would if they
were working with wax or resin.
FreeForm further streamlines manufacturing with features that
support:
- Visualizing undercuts – showing the product designer where
potential manufacturing problems may exist – and fixing them at
the touch of a button
- “Shelling” or hollowing out any design in seconds – without
fail
- Defining the mold’s parting lines – where the mold will open
after the plastic has hardened--especially irregular parting
lines on complex shapes
- Scaling up or down to a different size model of a figurine
at the press a button
“We’re already preparing to ship our next four box sets in a few
weeks – another accomplishment due to FreeForm,” Reidy continued.
“Now that we have standardized on FreeForm, we can literally go from
concept to final plastic parts in a matter of weeks. We can also
support multiple design and production processes at the same time
without missing a beat. For example, FreeForm allows us to utilize
the work of other digital sculptors and “fix” their parts for
manufacturing. FreeForm has proven to be everything we hoped it
would be – and more.”
“Wargames Factory’s approach typifies the ways that small, nimble
manufacturers can effectively compete against global firms which
have more employees, massive technology investments and costly
overhead,” said Joan Lockhart, SensAble’s vice president of sales
and marketing. “By adopting an all digital workflow from design
through manufacturing, entrepreneurial companies like Tony’s are
able to streamline the entire process and get high-quality products
to market faster. Wargames Factory’s business model is a real
success story, and SensAble is proud that the company made our
FreeForm technology the cornerstone of its design and production
processes.”
About Wargames Factory
Wargames Factory is a new company that designs and manufactures
high-quality hard plastic multi-part miniatures in 28mm (1/56 scale)
for wargamers, painters, modelers, and collectors. Based outside
Boston, Massachusetts, Wargames Factory uses recycled plastic and
partners with Triangle (www.triangle-inc.org)
a non-profit organization that serves thousands of people with
disabilities and employs over 200 “people with ability”. Find us at
www.wargamesfactory.com.
About SensAble Technologies
Founded in 1993, SensAble Technologies is a leading developer of
3D touch-enabled (force feedback) solutions and technology that
allow users to not only see and hear an on-screen computer
application, but to actually ‘feel’ it. With 33 patents granted and
over 6,000 systems installed worldwide, SensAble Technologies'
haptic technology is being used in applications ranging from
designing toys and footwear, to surgical simulation and stroke
rehabilitation, to dental restorations, as well as a range of
research and robotic applications. The company markets its own 3D
modeling solutions as well as its haptic devices and developer
toolkits to medical, dental, design, and manufacturing companies;
educational and research institutions; and OEMs. SensAble products
are available through direct and reseller channels worldwide.
For more information, visit
www.sensable.com.
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