How do we produce a miniature version of the various Flyer vehicles to distribute and display at trade shows?

The process for creating the Flyer scale vehicles begins with the CAD and developing a model that is the right balance of detailed yet printable. We initially tried scaling down the CAD from the full size vehicle and found that it wouldn’t be a viable option after various printing attempts. From there it was onto creating a new model designed and optimized for printing at that size being selective of what detail to include.

Resin Prints

I started off resin printing the vehicle to retain maximum detail at scale with the intent to paint each one as they would be a low quantity item.

Multicolor PLA Prints

As time went on the demand for the vehicles went up. The resin printed and hand painted variation became too time consuming so we looked into multicolor PLA printing to achieve similar results in a shorter time frame.

Optimizing Prints

Once we had figured out the correct scale and model for the vehicles I went onto refining the CAD for more optimal printing and visual interest. In addition, I developed another vehicle to expand on our lineup.

Final Model Designs

Display Case

Wanting to have the display case double as part of the packaging I created a frame with interchangeable base plates. Covering the plate in sand adds extra environment and detail.

Box and Sleeve Concept

Once the display case was figured out I needed to design the surrounding box. I looked into creating a tight fitting box with a cover that doubles as an informational brochure and a way to secure it all together.

Refining Packaging

Further improving and refining the box I landed on a clean and simple design. The packaging features the vehicle name, top view, scale and Flyer logo.

Flyer Vehicle 1:32 Scale Models at AUSA 2024

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