RP models help blind boy to see new home

A Moog product story

Edited by the Engineeringtalk editorial team Apr 7, 2008

Nine-piece model is built on a 3D Systems SLS system with DuraForm PA plastic, a durable and functional nylon material that has excellent surface resolution.

3D Systems Corp, the University of Louisville's Rapid Prototyping Centre and Harvest Technologies have teamed up to create SLA and SLS models of a home for a Louisville, Kentucky, family featured on ABC's "Extreme Makeover: Home Edition".

19-year-old Patrick Henry Hughes, the family's eldest son, is blind and disabled, overcoming challenges to become a musician and an inspiration to all those around him.

The "Extreme Makeover" team rebuilt in just seven days the Hughes family home to be safe and wheelchair accessible for Patrick Henry.

The show was taped last November and aired on ABC in late February.

Models of the home were built with 3D Systems technology by the University's RPC and Harvest.

Patrick Henry was given the DuraForm PA and Accura 25 models, two Go Pro material solutions from 3D Systems, so he could "see" the shape and layout through touch at the same time the crowd chanted "move that bus" and his family was experiencing the thrill of visually seeing their new, improved home.

"He would have had no idea what the house looked like or understand the floor plan to get around without our models", said Tim Gornet of the University's RPC at the JB Speed School of Engineering.

Just days before the family was returning to their newly renovated home, Gornet was asked by the construction company, Elite Homes, to build a model home for Patrick Henry.

With no time to spare, he called David Leigh at Harvest Technologies to build a second, backup model.

The deadline was 48 hours.

The university's RPC successfully built a nine-piece model on a 3D Systems' SLS System with DuraForm PA Plastic, a durable and functional nylon material that has excellent surface resolution.

It took 22 hours to build the 457 x 381 x 178mm model and another 10 hours for finishing touches.

The model was completed at midnight on Tuesday, delivered to the contractors at 0800 on Wednesday and presented to Patrick Henry later that day.

At the same time, Harvest Technologies, a full-service, high-capacity provider of Rapid Prototyping services, built a slightly larger three-piece model of the home.

The roof and ceiling were made with Accura 25 Plastic, a flexible material that simulates the aesthetics and properties of polypropylene, on a 3D Systems' accurate, reliable Viper Pro SLA System.

A Sinterstation Pro SLS System, known for its high throughput and speed, created the body of the house - built in DuraForm PA Plastic.

"The models were exactly what we expected and more", said Joe Pusateri, President of Elite Homes.

"The roof was removable so Patrick could put his hands in the house and feel where the walls were located".

"He lived in a nonhandicapped accessible home where he learned his way around".

"He was going to have to learn a new route in the new home".

The RPC model now sits in Patrick Henry's bedroom, while Elite Homes is displaying the Harvest model with plans to paint it to look like a miniature version of the house.