Andy Kossowsky is always looking for ways to improve the things he uses. An avid golfer and an inventor at heart, Kossowsky was dissatisfied with the typical driving range experience. He felt it was unfortunate there were not many advantageous places where he could put his golf clubs without the fear of having them get damaged or forgotten. That dissatisfaction was the impetus for creating the UpGrade Golf Systems products, where both his golf tray and range divider can conveniently hold up to 8 clubs.

Kossowsky found ProtoCAM by searching on Google for “plastic prototypes” and noted that ProtoCAM was located not too far away from his New York location. Kossowsky contacted ProtoCAM and spoke with Engineer, Ed Graham who guided him to ProtoCAM’s business partner Jim Eldon of Eldon Design Associates. Eldon worked with Kossowsky to move the product development process further along and create the 3D CAD model of the first product, The UpGrade Ball Tray.

ProtoCAM produced the stereolithography prototype in short order and on budget, which Kossowsky used to test and make adjustments in the size of some of the golf club holes. Another prototype was made and this second iteration tested out perfectly.

The second product made was the Range Divider. ProtoCAM again provided the SLA prototype from the 3D CAD model provided by Kossowsky and Eldon. The Range Divider was tested and an improvement in the anchoring system is now complete.

Accura 60 material was the stereolithography material used for all the SLA prototypes.

Kossowsky comments that he “feels spoiled by the experience” because of ProtoCAM’s great service and he “can’t wait to work with ProtoCAM again in the future.”

For manufacturing the products, Kossowsky is now sourcing to make the product using injection molding with polyethylene.

About the UpGrade Golf Products
Both tray and divider provide upright storage and easy access for up to eight golf clubs regardless of grip size. The use of these products eliminates lost clubs that may be left behind or damaged from leaving clubs on the ground or against a fence. The Ball Tray can hold in excess of 90 balls and the Range Divider will allow for an improved area to a person to organize the balls to be used on the range. Both products have a designated area to be used for advertising where the cost of the advertising space can essentially pay for the cost of the tray/divider and in time, will make money for the driving range owner. Both products are patent pending.

About Andy Kossowsky
Andy is a golf enthusiast, author and inventor of both golf products and a unique playing style. Andy invented The PowerSlot Swing, www.powerslotswing.com. Various articles have been published regarding Kossowsky’s swing method, including pieces in publinksgolfer.net and worldgolf.com, and a YouTube video. Along with working on making a feature length video and getting his book published, Andy has also invented a putter and is working on bringing it to market as well.

Check out the Upgrade Golf Products online at www.UpgradeGolf.com.

Labels: large parts, plastics engineering, product development, rapid prototyping, SLA prototype, stereolithography

One question that I get asked on a regular basis is "How large a part can you build?" Rapid prototyping machines have a fixed size, and many of them have a relatively small area where they can build parts (their "build envelope"). Our largest machines, the SLA-7000s, have a build envelope of 20" x 20" x 23", but this doesn't limit the size of the parts we can deliver. By sectioning your CAD model into 20" x 20" chunks, we can build parts of any size.

When we receive a large part for quotation, we cut it into sections in a way that minimizes cost. The typical factors we consider are total height of the platen (if you don't know already, we use height and volume to estimate cost, and we adjust that based on part complexity), number of platens, and number of cuts. We then price it based on the machine's run time and finishing/gluing time, so you get a quote with the information you need to know -- how much it will cost you, and how quickly you can have it.

Once you give us the job, we go back and cut the part again, this time adding lap joints for strength. This step allows us to produce a part that is very strong along its seams, and that can be positioned back together accurately. For parts with complex cutting requirements, this step may be responsible, partly, for any additional lead time (beyond our typical 2-day turnaround) that you were quoted.

After the parts are cut in CAD, they are prepared for build in the 3D LightYear package, a proprietary software package built for stereolithography machines. This step comes up with the set of instructions that the SLA machine uses to build. (Conceptually very similar to the G-code used to run CNC machinery.)

Once finished, the parts are drained, removed from the perforated metal platen, separated from their supports, rinsed of excess resin, and cured in a UV oven. After this step, the lap joints are sanded so the parts can be fit together. Once the fit has been adjusted optimally, the parts are bonded with one or both of the glues that we've settled on using after years of experience. This leaves the seam with excess material and sometimes slight discoloration. The seam is then sanded until it is smooth to the touch. This process is repeated for each piece that needs to be glued together. Often times, our choice of glues leaves the seam stronger than the part.

With this proven process, we can deliver you prototypes of any size, from dashboards to wind tunnel models to tractor seats to chair backs. Large parts require extra care when shipping, but we have great experience doing that, from customers local to us in the Lehigh Valley to those on the other end of the country in California or Washington.

If you have any questions, call (610)261-9010 or leave a comment here on the blog.

Labels: CAD, cutting, large parts, prototypes