ShapeMaster got its start as a prototype shop designing and manufacturing small and medium sized parts in various gauges of plastic for designers, engineers, entrepreneurs and inventors. Featured here are various projects that required extensive research, “outside the box” creativity, product development, and reaching beyond our limitations to deliver products that meet the needs of our customers.
We encourage you to bring your conceptual ideas to ShapeMaster where we will work with you every step of the way to ensure complete satisfaction and deliver what you once thought to be the impossible.
3D PRINTED MESSERSCHMITT COMPONENT
Client: Midwest Aero Restorations
A local company was restoring a Messerschmitt Bf 109 and asked us to help them recreate a part from the motor so that it could be recast.
They loaned us the part so we could 3D digitally non-contact scan it, and then 3D print. We then measured the plastic printed part to prove that our scanning and CAD work to do some repair work to the metal component had not distorted the part and then provided both the CAD files and the 3D printed part to our customer.
We can now use that same 3D printed work to send off to an investment casting company and have these parts cast in the same metals as they would have been done in the 1930’s when the airplane was made.
SILICON WAFER DIPPER
Clients: Various institutions from around the world.
This Teflon dipper device is used to aid in the coating process for silicon disks. We have made them as small as 2″ in diameter and as large as 8″ in diameter. We can even custom make them to your specific requirements. Give a call with your design. We are the experts in PTFE/Teflon design and fabrication!
Concentrated chemical cleaning dispenser made of ABS plastic. The front locking door is made of polycarbonate.
‘RONAS AND RITAS’ TRAY
Client: Reisigl Associates, Inc.
We have made custom trays for many companies. One such example was the `Ronas and Ritas` tray we made for Reisigl Associates, Inc. a design and branding agency. This tray is used to hold a bucket of beer with ice in it, as well as to hold a pitcher of margaritas. Also, the center pockets are used for a place to keep limes and to hold salt.
Client: Eden Park
Holds glass panels.
Client: Local University
This piglet cage was designed for a local universities` Animal Science Research Team and is a good example of our metal working and plastic machining abilities.
THE POSTURE RACK
Client: Ultimate ChiroCare
We have been working with Dr. Cammisa since 2010 in developing The Posture Rack. This will allow for upper body core strength exercise as well as lower. Using 8020, we were able to engineer and construct The Posture Rack to his specifications. The Posture Rack will take the Power Plate to a whole new level. Please visit: www.ultimatechirocare.com for more information.
Client: Pharmaceutical Company
We recently completed the install of the 8020 guarding we engineered for a large pharmaceutical company.
REVERSE OSMOSIS WATER DISPENSER
Client: Water Island
In conjunction with President and CEO, Dean Robinson, also named Entrepreneur of the Year by President Ronald Reagan, we developed six prototype reverse osmosis water dispenser units. The challenge: Design units that would perform three of the five steps of the reverse osmosis process while allowing the dispensing of water into two one-gallon jugs or one five-gallon and a one-gallon jug simultaneously. We accomplished the challenge and did so by taking up less than a 4-sq. ft. footprint of space in a grocery store. In addition to the housing, over 40 component parts were produced by ShapeMaster. We then assembled each system which served as a supply unit to the produce case, baker proofers, drinking fountains, ice machines and other locations throughout the grocery store. The cabinet is made entirely of ABS thermoplastic molded over a one-piece tool, demonstrating just how creative we can be. The texture is fine and allows for easy cleaning, yet offers a look that hides small scratches and fingerprints.
HOUSE METER TRAYS
Company: Landis and Gyr
These trays are designed to hold four meters within the factories during the manufacturing process. These meters are used to measure electricity use.
FABRICATED POLYCARBONATE BOXES
Client: University of Missouri
We fabricated these boxes to hold a metal plate and for research use. The bottoms are made of polypropylene and the rest of the box is made of polycarbonate.
Client: The Vineyard Church Urbana
ShapeMaster recently designed and engineered a new product out of 8020 for a local church.
Problem: Old podium with one height for various pastors. Existing systems had been music stands, and an older wooden lectern; however this did not have a logo on the front nor an opportunity to height adjust.
Solution: Using 80/20, we created a professional and innovative product that adjusts for the height of different pastors while displaying the logo of The Vineyard Church. This new unit was created from 8020, aluminum panels, machined plastic, and custom powder coating.
STAR TREK CHARACTER BOX
When we say we do unique projects, we really mean it! One of the coolest of those projects was when we were asked to fabricate a StarTrek doll box for a life-sized individual. Our customer wanted to arrive at a star trek convention as his character in a life-sized doll box. This was no problem for our crew.
Client: Engineering Firm
These were originally created to be made into signs advertising a brand`s product.
TOMATO STEM ICON
Client: Pizza Restaurant
A flying tomato serves as the icon (or logo) for a local pizza restaurant. The challenge: Construct a tomato stem out of molded plastic (vs. former models of fiberglass) for use on top of their red pizza delivery vehicles. The fiberglass stems they had used in the past faded and they preferred something more realistic as the fiberglass versions had customers asking if the icon was a chicken foot! Due to the size of the delivery vehicles, the tomato stem and leaf assembly needed to be over 40-inches in diameter. At that time, our equipment was not capable of forming something so large. Thus, we opted to form six individual leaves to first create the leaf assembly and then created the stem by forming two halves and bonding them together. The leaves were bolted together and the stem was bolted to a bracket attached to the leaves. Since the leaf assembly was bolted together, we were able to modify it later when our client decided to adapt the tomato stems to be used as patio umbrella toppers.
PORTA POTTY BANKS
These are 10th scale models of the Polyjohn PJ3. They stand about 10″ tall and are banks. We can private label these items for special events. Custom colors are available in lots of 320 units.
MOOSE HEAD MASCOT
Client: Promotional Activities
The moose is a man sized suit for people to wear in parades and promotions for various companies.
CNC FABRICATED BASKETBALL MEN
Client: Basketball Training Device
These custom fabricated basketball men were developed for a coach in Decatur, Illinois to help players become better shooters. Through the use of CNC plastic routing, we used a combination of pipe and machined special rings and bosses to mount pipe to stock injection molded bases.
TIN CEILING RENOVATION PROJECT
Client: Insurance Office in Historic Building
An insurance company purchased a building to restore for their new offices. When the drop ceiling was removed they found the original tin tile ceiling; however, a number of tiles had been destroyed or removed during a prior remodel. This left them disheartened. Then, they discovered ShapeMaster, and agreed to send us one each of the metal tins that were required to reconstruct the ceiling. We made plaster molds to replicate the metal tins and set them up for vacuum forming. We molded white polystyrene high impact paintable plastic for the tiles which could be easily trimmed by laborers in the reconstruction process to ensure an exact fit. A wonderful story that ended in a beautiful restoration.
CUSTOM MOTORCYCLE ACCESSORIES
Client: Suzuki M50
We are passionate about Suzuki M50 motorcycles and thus began designing and manufacturing parts for M50 bikes. Our custom chin spoiler was created to replace the stock Suzuki radiator cover. Following the curved design of the M50, our custom chin spoiler results in that sleek look you have always wanted, creating a little “attitude” on the front of your bike. Manufactured of ABS molded plastic, our chin spoiler features either a silver mesh or honeycomb grille finish and comes painted in flat black, gloss black, or wet sanded and ready for the paint color of your choice. Add flames, decals, or bolt on neat metal items to make your own statement. The air flow is great and you’ll experience no problems with overheating. Simply bolt on the black powder coated custom metal bracket we include and in less than 15 minutes your bike looks hotter than your neighbors and cooler than any other M50 on the road, until they too buy a ShapeMaster custom chin spoiler! Product tests have been performed at speeds up to 105 mph on rough roads, including crazy peg dragging. You won’t find a better designed product!
CUSTOM ELECTRONIC ENCLOSURES
Client: General Industry
We originally designed these cases for electronic enclosures and they have since become a popular item for hobby and miscellaneous production applications. We currently make two sizes, including a business card sized box which was originally developed as a hand-held joy-stick type enclosure. Many companies are using this box for products in commercial and consumer markets. The top of the card box overlaps the bottom, which give it adjust ability in overall height if needed. The top can be fastened by adhesive, plastic rivet or sheet metal screw. Our larger box features dimensions that will hold a 5.25″ item, from 1.5″ to 2.125″ in height. Both boxes are available in small quantities, white or black ABS with a wall thickness of .050″. The standard exterior surface is a fine texture; however, a smooth surface is available as well. We also offer custom hole, slot or square hole punching, drilling or routing with all stock electronic cases or trays.
CROWS FOR FUNDRAISING PROJECT
Client: Danville, Illinois Theater
We designed these crows to help raise money for a local area theater where icons such as Dick and Jerry Van Dyke and Gene Hackman have performed. The Danville, Illinois area has a problem with crows and they wanted to incorporate the much hated crow as a drawing card for the town to rally help for the theater and to have a parade. Scarecrows walked down the street, and local businesses painted up and decorated large crows to display in front of their businesses on heavy concrete stands. The crows were wonderful to look at and helped raise the needed money for the theater.
This device is used to assist in hanging wall decor.