Thunderbirds
We were heavily involved in the design / manufacture process from an early stage. With the CAD technology we use, we began building from very early stage virtual reality concepts as options for the production company - Tracy Films. These models allowed the concept and visualisation of what the mechanisms would look like and how they moved the parts.
We worked closely with the sponsors, Ford who designed and supplied us with all the basic exterior surface information to start with. From the supplied CAD surface data we had to design a light weight rigid composite structure which would incorporate all the roof and door mechanism designs. The purpose of the composite structure was primarily to support the body on the chassis and provide attachment for the various other parts required for the operation of the car.
The added advantages of the composite structure meant we could independently build and assemble the structure without any of the chassis or body panel parts.
Once the structure design had been completed the CAD surface data (for the
interior structure) was supplied to Ford which allowed them to complete the interior design.
This technique meant that all the car's main components could be manufactured simultaneously as large sub-assemblies. Once all the main sub-assemblies were ready we could then complete the assembly work of attaching the structure to the chassis and the body onto the structure.
The concept of design and assembly of this car can be applied to almost any film vehicle and it will save you time and money!
