kostas georgi o u clay + alias portfolio
Based in Newcastle UK. kostas.georgiou@icloud.com mobile phone:07577850890 uk.linkedin.com/in/kmg170/
EDUCATION Currently Studying Transportation Design at Northumbria University. 2010- 2014 (Graduation on 15th July ‘14)
SKILLS Proficient in Making a 2D Image into a 3D Model, Using traditional Model making Techniques. Working to CAD Data to create 3D hard/clay models. Competent Clay Modeller Adobe Creative Suite Alias Automotive Solidworks 2013 Keyshot Rendering
REFERENCES
EXPERIENCE Xenophya Design- July 2013 till Present
Internship developing skills in clay modelling and CAD. Working on live projects with triumph and personal company projects such as the clay model for the Redbull Soapbox race. Learning to take CAD data and translate that into a prototype/clay model.
After internship I collaborated with xenophya building clay models for Royal Enfield and Triumph. Currently working on a full size Side by Side ATV
Aeon Sportscars 3 months 2012
Tasked to re-develop the Old GT3 Model and Manufacture a prototype body kit by hand. This included bonnet, main cabin and rear end. I developed a new roof and crafted the whole body using traditional model making techniques in 3 months. You can find my work in the November 2012 Issue of Complete KitCar. There is a 4 page spread on my work.
Alanco Agricultural- 2 months 2012
I was set to re-design the cabin of the Sprayranger 300D Model Alanco Currently makes. My design will be in production in 2013.
Mark Wells/Ian Wride- Owners of Xenophya Design. info@xenophya.com t. +44 (0) 1670 735588 m.+44(0) 7810 436 189
xenophyadesign
INTERNSHIP - 4 MONTHS
Redbull Soapbox This was a light hearted project that rapidly became serious and very labour intensive. What started as a bit of fun turned into long hours and some serious teamwork. This opportunity gave me my base skills in Clay-Modelling working from a CAD Model, and spurred a passion for working with clay. Along with the clay, I learned to work in a team and how to make polydor casts of the model, translating into a fibreglass shell. And to top it off, we won the competition in London at Alexandra Palace!
Working from CAD Templates were built using section lines from the CAD model. This allowed me to see the profile of the body. The sections were pasted to MDF board, cut out then placed up to the clay model. I took figures for x/y/x and aligned the MDF up to the clay in the correct position. The CMM arms ensured the models accuracy.
We began by creating the armature for the bottom half of our clay model, the aim was to create the underside in clay, take a mould from that, then to model the top surfaces. We used the CAD data to cut templates and sections, then filled them with foam before skinning in clay.
Using the CMM arm, profiles and templates were fitted and positioned from the CAD data. This allowed us to accurately build up the surfaces to give enough room for what would be the inside of the hard model.
To create the top half, sections were taken from the cad data every 40mm. This gave us the profile and shape of the top half, which we then glued together and secured to the now complete bottom section of the model.
The top sections, glued together after a long night of gluing and organising! Even just enough time for a team picture with an almost 1st completed 1st skin of clay on the model.
The top coming together, as we slick back and prepare the clay for moulding. Tape lines were used to create boundary edges to work to.
We divided the model into sections, and began to create what would be a 9 part tool. Polydor was used for the mould, section by section we prepared the clay and applied the Polydor to create a working mould of the clay.
And from the moulds we began to wax and apply fibreglass to create 2 fibreglass shells. One for top, and one for the bottom. These would then combine and fit to the chassis of the vehicle. The fibreglass was then trimmed to shape.
After trimming, the shells were sanded down and then smoothed back. We were trying to create surfaces with as few imperfections as possible. Body filler was used and the whole body was flatted back with wet and dry.
Once we had gotten the shell to a high standard, it was time to paint the model ready for race day.
The whole team together, standing by the finished fibreglass soapbox complete with chassis and vinyls.
REDBULL SOAPBOX RACE Almost 4 months later, we had a working fibreglass body and chassis to go with it. A long and difficult task, but very rewarding in the end and allowing me to develop skills in Clay Modelling, Fibreglass Moulding and Hard Modelling.
Sportscars
INTERNSHIP - 3 MONTHS
Prototype Build Tasked to re-design the old Aeon GT kit-car. This project was challenging from start to finish, with the proviso of only changing the mid section and enough of the front and back to blend into the new middle. I had to source new parts for screen replacements, then hard model the entire car to develop a set of working fibreglass moulds.
AEON GT3 ALIAS MODEL
Presentation Visuals I created the presentation visuals using Autodesk Alias to present before modelling commenced. Rendered in Luxion KeyShot 4
AEON GT3 ALIAS MODEL
Sportscars
hard model build
Hard Model Prototype With the design adapted, the time came to build a prototype, based on the existing chassis. We took the chassis, centred it up and began cutting the old body to change its features. We worked primarily in fibreglass, learning to make moulds and create a hard model using traditional modelling techniques The model had to be built within the eyes of the law, all standards and safety regulations had to be followed as needed for a Kit-car.
The original model GT2 had a very low roof that made it hard for any tall person to fit in. Our initial aim was to change the window and create a new inclusive roof.
Beginning with an initial and rough cardboard stage, to try and visualise the new roof line. I worked in card at this time to get my head around what I wanted to achieve. It served a brief purpose as a rough tool.
Plotting the Windshield We began to size up the kind of windshield we wanted by arbitrarily layering fibreboard over the car. From here we had a rough line we liked, then began to lay out a tape line and take measurements. Once set and ready to go, the time came for cutting out the old screen and bracing the car. Once the old screen was cut the car had no structural rigidity. We had to find the centre again, and brace it accordingly.
Making the Screen Surround We sourced a screen that suited our needs, the actual screen was one from a lotus Elise. This was large enough to provide the extra headroom, and massively increased the field of view for the driver. Once the screen was found, we took a fibreglass mould of the edges, leaving 30mm around the screen mount. This allowed me to fashion this to the current Aeon GT in the best position possible. The windshield would be simply glued to the mount I made once it was full incorporated in the new fibreglass midsection. I fashioned a detail in the front of the footwell, just under the windshield mount for the wiper unit.
The roof had to be made in a higher position, on the buck to allow for more headroom, the biggest challenge was making sure that we could get a curvature to a straight edge. We built wooden supports, then foam edging. Once the support was done, we layered fibreglass matting, applied the resin and when it was dry, the roof was skinned in body filler.
Spraying the Buck The buck had to be sprayed and finished to a high standard before we took it to make a fibreglass mould. It was here that I used a spray gun for the first time. Whilst waiting for the buck to dry and the fibreglass mould to set, we began to make the door supports, in preparation for creating 2 identical scissor opening doors. Fibreglass was layered over the door supports, then body filler was used to smooth the surface of the door. From here we took a mould of the door, with the aim of taking a fibreglass part from it.
foam modelling v8 engine
QUICK FOAM MODELLING This project was to develop skills in working with model board. Working quickly to create a simple model that fit together with as little glue/filler as possible.
final year model all terrain vehicle
Scale Clay Model My final year model is currently underway and I have designed an ATV for the Indian market place that creates platform for development by outside companies/prospective owners. It has a power take off unit and also serves as a generator to give power to rural areas. The model is currently being made, with a lot of time being put into surfacing my clay and having a finished painted clay model. I made an Alias model of my chassis to get the packaging and proportions correct before creating my general assembly drawings. For parts like the handlebars and other small details, I made a model in Solidworks and had them made on a 3D printer.
Alias model - chassis This model was created in Alias to show the generator unit and power take off. It allowed me to understand the model and its packaging before I took it into clay.
Solidworks to a solid model My model is a half scale quad, do finding and sourcing handlebars was immediately an issue. I created the handlebars using Solidworks for a solid model, then sent it to print. After 19 hours I had my handlebars in 3 separate parts. I later put them in an agitating alkaline solution to remove the black support build. Once placed onto the Quad they really help to set the tone as a half scale ATV.
The Chassis I had bought for my model wouldn’t fit my GA Drawing of the model. I had to retrofit the back end by using an angle grinder to cut the tail unit off, then I re-welded the chassis back together with angle iron. I used the CMM Arm to ensure perfect alignment.
Building the Armature I created a brace for the ATV that fit around the chassis, this was fixed to the baseplate to stop the model moving around. It also helps to keep the ATV in a central position for reference points and measurements. The model can be simply lifted off when the time comes to move it. Once the Chassis was cut and fixed to the baseplate, the time came to build the box section/armature. I cut MDF to shape based on my GA Drawings then packed out the form in blue modelling Foam.
WORK IN PROGRESS
Thank You Thank you for taking the time to look through my portfolio, I hope to hear from you soon. Kind regards, Kostas.
Kostas Georgiou mob: 07577850890 email: kostas.georgiou@icloud.com linkedin: uk.linkedin.com/in/kmg170/