This is a long story about #Family, # Loyalty, #Technology and #Friendship. Bear with me, it’s a long one… I moved to Toronto in 2001 to start a company with an old friend. My 10-year-old Volkswagen GTi would not meet local safety standards and with two very young boys, we needed more space. We bought a brand new 2001 Honda Odyssey – built on the same side of the border in Alliston, Ontario.
Vanessa in its glory
We took delivery on September 13th, 2001 – just two days after 9-11, something I will never forget. For the next decades (yes…), Vanessa (Van-essa… 😊) became the #family hauler. First for Canadian adventures, trips to see the #family in Maryland and Massachusetts, then moving back (wow does it have space!). Vanessa than took us on long trips to Florida, Georgia, West Virginia, the Carolinas, Kentucky, New York, Massachusetts, among others. As the boys grew, she drove them to elementary, middle, high school, and sporting events. They both learned to drive on Vanessa. Then, it was off the college. With over 13 years on its belt, it became the spare car and the RPM Tech hauler. At one point, it was filled to the brim with large enclosures for a customer. It even took Drew though a blizzard while visiting a customer in Virginia. During Covid, it became the emergency moving van, helping both the boys move from Kentucky and Florida back home from college. Talk about #loyalty.
Today, Vanessa still provides reliable transportation when one of the cars is out of commission. With 476,500 kms, or 296,100 miles, it just keeps going. So why would anyone care? That’s because I’m a car guy and started down the tumultuous effort to make a scaled model of the van – because I could. Anyone who knows me knows I’m a #carguy; I am passionate about everything about cars. I have an almost complete collection of my cars, all 1:43. I didn’t have one for Vanessa and the van is not a big interest to collectors, so no model… What next?
My almost complete solution
I initially thought I would look for a #3Dmodel from one of the various 3D model sharing sites. There was a render but it was not a printable file. We don’t have all the software needed to solidify the model and honestly this was not going to be interesting. Still, I wanted a model. After all, while unexciting, Vanessa was a huge part of the family and deserved to complete the collection. This is where #technology comes into play. We are often asked to reverse engineer designs and concepts and work with an extensive number of tools and software, and when needed a #network of experts. Why not scan the van…? I reached out to my friend Michael Raphael, Founder and CEO of Direct Dimensions – an everything to everyone #3Dscanning and reverse engineering company in our backyard, Owings Mills, Maryland. Michael is a good #friend and offered to scan the car for us. Mind you, we have scanned things before for quick and dirty checks. The reality is that every single situation requires a specific tool and the output then requires additional processing with software used for each desired output. If you don’t scan daily, and always scan the same kind of items, it’s a big effort with a huge learning curve. That’s why we use Direct Dimensions for every project we need to scan an accurate model.
One step in the scanning process. Unlike other subjects, Vanessa did not move during the shoot.
Vanessa was scanned and the #3Dmodel processed for us to be able to print. Even with all the post processing, we still needed to adjust the file, scale it as needed and then slice the model to print accurately.
This is my van, with all its minor defects, misalignments, dents… on Direct Dimensions’ web site
That’s where my colleague Andrew decided to go above and beyond.
The 3D model imported into our CAD system
Initial slicer import and set up, with support
In addition to processing the file, he also edited it to print on our Prusa #fdm printer. He took advantage of the 5 heads to print the van multicolor! That was a pleasant surprise. Of course, the printer did run into some minor issues, but not without completing the print all the way.
Model colored in the slicer software
The Prusa at work
The result is absolutely awesome. Katie even clear coated the windshield.
Even the license plate has the RPM Tech logo on it
Side by side – well not exactly…
This gives a better idea of the scale…
Ready to add to the collection
For people who have not used a 3D printer, the process is rarely a load and print… Things happen. The model looks fabulous but I was interested in seeing a smoother finish. That’s when another friend, Greg Paulsen at Xometry offered to print the van using a different process, #slsprinting.The result was very cool looking.
SLS printed model – very accurate
I know Greg has some other ideas, but now I can finally say I have all my cars in miniature… Thank you to all who helped.
The (almost) complete collection – one on its way and one that will never be added…
With today’s tools, the sky is the limit. There is no doubt that one person could have done this on their own, we have so much technology available. But the reality is that this result is from a comprehensive team of experts with their specialized tools. Thank you to all who helped me complete my collection and turn my curiosity into this amazing result!
#rapidprototyping #3dprinting #3dscanning #teamwork