Brian Petty
Ogle Models Zodiac Aerospace
With over 100,000 flights made every day across the world, millions of people spend hours on end sat in aviation transport. Ogle Models, a UK-based modelling and design company, teamed up with Zodiac Aerospace to design a more comfortable solution for the travellers, tourists and businesspeople who tackle the turbulence of air travel.
Using stereolithography 3D printing technology and CNC machining, the collaborating companies produced full-scale exhibition model of a business class aeroplane seat.
Ogle Models and Zodiac Aerospace, a leading manufacturer of aerospace equipment with an extensive portfolio of aircraft seats through its Zodiac Seats division, targeted the Aircraft Interiors Expo in Hamburg in April 2017 as the location for its first showcasing. The model was to be built between two side-by-side client-supplied production business class seats, and with sufficient strength and rigidity to appear to float above the floor with minimal contact points between seat frame and floor.
Fibreglass was selected ahead of model board as the primary production material due to its lightweighted nature, and comparatively strong properties. Strength and weight were two of the most important factors – the seat frame needed to be strong enough to endure testing but light enough to be moved with ease. A third benefit of the fibreglass material was its capability to neatly store electrical cabling and wiring, which is necessary for such things as lighting and air conditioning.
Edu Van Gelder
Ogle Models Zodiac Aerospace
The CNC work for the seat was done using several three-axis machines. Since the geometry was not complex, there was no need to harness the four and five-axis CNC machines which Ogle possesses. During the CNC phase, precise cavities were created within the seat model to enable SLA printed parts to provide additional detailing. SLA was the selected technique because it can meet an accuracy of ±0.1 mm per 100 mm. 3D printing was also used to print the trim, but most important to the aesthetics of Ogle and Zodiac’s premium product was the surface finish which ensured the model was as visually similar to the production seat as possible.
Then, the functional aspects of the model, including LED mood lighting, flat screen TV, air condition duct, and other electrical parts, were added. All were controlled by a single remote, per the client’s request, and the cabling ran under the floor, the complete model able to split into three parts (all connected) which helped to limit physical involvement when setting up the model.
Fabrics and leathers supplied by the client added the finishing touches to the visually-accurate model. The final stage was just to fit and bolt down the model between the production seats, ensuring they did not rub as they ran through their full motion of travel.
Edu Van Gelder
Ogle Models Zodiac Aerospace
And with that the project was complete, Ogle’s range of manufacturing equipment and Zodiac’s proficiencies in aircraft seat manufacturing ensuring no compromise on aesthetics, durability and overall quality.
“With the ever-increasing demands of airline customers to improve product functionality, quality and customer experience, Zodiac seats UK relies on partners such as Ogle Models to showcase product innovation the best possible light,” commented a Senior Design Engineer at Zodiac Aerospace. “Zodiac Seats UK is a premium manufacturer of Business & First Class seating systems, supplying to a global customer base and working with some of the world’s most premium airlines.
“Partnering with Ogle Models has meant Zodiac Seats UK can commission superb quality prototypes, essential in securing the confidence of major airlines, that Zodiac Seats UK will deliver a top-quality product. Ogle was selected by Zodiac Seats UK based on their reputation for applying extensive knowledge of developing prototypes from initial design conception to final product execution.”
