CNC Router Services
We produce most models in a week or less. Specialty materials
that we don't have in stock may take longer. Small models can
often be produced in two or three days. Large, multi-section
models are likely to take more than a week.
Our Router's bed size is 48" x 96", but can route
slightly larger sheets of material.
Our standard foam is 15 lb/cf polyurethane but will route
just about any material that you request. We believe this density
and special foaming procedure provides for the best model appearance,
with a good balance between durability and weight. The higher
density is especially important if you're not planning on special
model protection or on casting a reinforced copy. The polyurethane
formula is ideal for a variety of finish techniques.
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1. How long does a topographic model take?
We produce most models in a week or less and hand deliver
by our inhouse courier service if you are in a 25 - 50 mile
radius of Lowell, MA, ship them by overnight or two-day express.
Small models can often be produced in two or three days. Large,
multi-section models are likely to take more than a week. Any
architectural model details are up to you.
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2. What do you charge for your models?
Our charge is based on the time and materials, which are
determined mainly by two factors: the overall, bounding-rectangular,
volume of the model (not the "net" volume) and the
complexity of the model shape. Once you know the size and contour
"step" you require, the following guidelines should
help provide a preliminary "order of magnitude" estimate:
In brief summary, models usually cost between $300 and
$500 per cubic foot of overall volume. This assumes our 8lb/cf
foam, wood crate and delivery.
Our "average" model costs about $400 per cubic foot
of gross overall volume. [Example: 30" x 40" x 2.5"
overall, with about fifty steps cut at .040" each - costs
under $700, delivered. Multiply dimensions 30"x40"x2.5"
and divide by 1728 in3/ft3 to calculate overall volume of 1.74ft3.
Then, multiply 1.74ft3 by $400/ ft3 to arrive at an estimated
total cost of $696]
At one extreme, models which are "large" (over ten
cubic feet gross overall volume and over 3" deep) and "simple"
(with "bold" contours - steps deeper than 0.100")
sometimes cost as little as $100 per cubic foot, delivered.
At the other extreme, models which are "small" (under
two cubic feet gross overall volume) and complex (with "fine"
contours - steps between .020" and .030" depth, or
"sanded smooth") are not likely to cost more than
$500 per cubic foot of gross overall volume, delivered.
This is US currency and includes domestic delivery. These guidelines
do not apply to models under two square feet in overall plan
area, under 2" in overall depth, with exaggerated vertical
scale, with unusually fine detail, or with illegible drawings.
These estimates do not include sales taxes which may be applicable.
CAD work can add to these costs, depending on the quality of
the data which is available.
Please don't hesitate to contact us for more guidance and help
in your planning.
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3. What kind of foam do you use?
Our standard foam is 15lb/cf polyurethane foam by the manufacturer.
We believe this density and special foaming procedure provides
for the best model appearance, with a good balance between durability
and weight. The higher density is especially important if you're
not planning on special model protection or on casting a reinforced
copy. The polyurethane formula is ideal for a variety of finish
techniques, unlike expanded polystyrene foam. [Lighter foams
cost less but look coarser and require more protection.]
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4. Can I get a topographic model sample?
Just phone, write, or e-mail, being sure to include your
name and address. No charge if ordinary US Postal Service delivery
is acceptable.
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5. Can you use other foams or other materials?
Yes, we will work with any rigid foam. We would strongly
advise, however, that you be very careful of any foam under
6 lb/cf. Such light foam requires very special care and protection.
Check with us about extra time which may be required to order
the foam of your choice. If you have computerized data, in suitable
format, our CNC router will cut models and prototypes from most
any material softer than steel.
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6. We're a large "full service" architectural
model shop. Could you keep our relationship secret?
Certainly - this is not unusual. You might be surprised,
however, how easily your clients would appreciate the value
of specialization these days. This is especially true with almost
everyone using fax, e-mail and overnight delivery services.
A lot of architectural model builders find that they don't use
their "foam carving machine" often enough, and they
are delighted to be able to reclaim the space and keep their
shop much cleaner. [Very few people require that their home
or office be constructed by a "full service" builder.
Just think of us as "the bulldozer guys."]
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7. What file formats do you use?
We can use ACAD, Solidworks, Rhino, dxf, stl, iges or just
about any file out there. Call or email us prior to sending
for an estimate.
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8. Will you finish our architectural model for us?
Sorry, but we're specialists - producing shapes and sometimes
painting them one color. In this way, our clients do not have
to worry whether our best work is really limited to the select
few models we finish ourselves. We don't compete with the people
we serve.
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9. What kind of paint can we use?
Any paint. No ordinary coating will damage the foam and
we've heard good reports on all kinds of paint. The only warnings
we've heard pertain to models which people coated with relatively
thick coatings of epoxy or urethane. It seems that coating shrinkage
can cause cracking (and even warp a model).
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10. How can we get an accurate estimate of cost and
time to produce a model?
The ideal would be to send us a file. We can generate a
tool path to give you a quick estimate. If schedule or convenience
requires, however, we can work with sketches and/or description,
by voice, fax or e-mail. The key information is the plan dimensions,
the scale, the step required, the amount of relief, and some
description of the complexity. You can reach us by:
voice: 1 978 828 6379
mail:ACE Laser
36 Puffer st
Lowell,MA 01851
email:sales@acelasersupply.com
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15. Is the dust hazardous to breathe?
We haven't found anything to indicate that the dust is more
hazardous than ordinary environmental and shop dust, which should
be avoided.
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16. Is the foam flammable?
It is produced with a fire retardant ingredient. This reduces
the hazard to a low level for most model installations. Certain
applications, such as a large foam model which is wall-mounted
in a public space, should be studied carefully to determine
if the surface coating provides additional protection from ignition.
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17. What kind of glue can we use?
First, no ordinary glue will damage the foam itself. Since
the foam is "closed cell," it would be hard to predict
the speed with which air-drying adhesives will solidify. Due
also to the general need for "gap filling," capability
we most often recommend two-part liquid epoxy, selected so that
you have enough working time. Contact adhesives are also acceptable
under some circumstances, but you may need an extra coat on
the foam side, and you should avoid joining rigid components
unless they have large contact areas (without forced bending).
[An obvious warning is to avoid letting an adhesive get on a
surface which is to be exposed - unless it doesn't matter that
the texture is changed by cell filling.]
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18. How do you dimensionally compensate for the steps
which you sand off?
Our Router does 3D contouring. We offset from the contour slightly
to compensate for sanding.
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19. How easy is it to carve your foam?
The foam is easy to cut with ordinary woodworking and carving
tools, including your Exacto #11. It's also good to sand.
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20. What contour interval do you recommend?
This would depend mostly on the purpose of the model, on
the scale, and on the amount of relief across the model. If
the relief is less than 2" (50 mm) or a detailed building
model will be installed, you are likely to prefer fine contour,
maybe .020" - .040" (0.5 - 1.0 mm). If the model is
deeper than three inches, or if it's just for "massing"
study, contours of .60" - .10" may be acceptable.
In selecting a contour interval, keep in mind the following
general tendencies:
finer contours (and sanding) tend to diminish apparent
depth of relief
coarse contours dramatize relief
the reduced drama of fine contours is less likely to draw attention
from featured architecture
sanded sites seem more "realistic" than stepped sites,
but make it harder to "read" the shape
contour interval and building model detail are related, avoid
finely detailed buildings on coarsely contoured sites
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21. Do you provide realistically smooth models, without
steps?
Yes. We produce these by CNC router. The determining factor
is often the quality of the contour data. If it is good, the
relief can be milled to a smooth surface and then line information
can be engraved over the undulating surface, according to a
2D vector file. For example, paths, roads and property lines
could be engraved with a cutting tool of .005 diameter, to a
depth of .01" .
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22. Do we need to provide perfect contour drawings?
No. We certainly recommend checking the drawings to avoid
serious errors, omissions and ambiguities. We produce a 3D"shop
drawing" prior to milling. This helps us work out problems
with our clients, often with the help of faxed inquiries and
clarifications.
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23. If we only have five foot contours and we want
a model with 1' contours, do we have to draw them?
No. We will be glad to interpolate contours in between.
It would be good, however, if you check for special conditions,
such as entries and terraces, where you may want to provide
spot elevations to guide interpolation.
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24. How can you help us with building installation?
We provide "rough excavations" to whatever depth
you request. We generally recommend cutting to the "lowest
adjacent grade" and leaving a little foam "trim margin."
When good CAD data allows, our CNC router produced models can
be cut with accurate building footprints, or a setback which
you specify.
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25. Should we exaggerate the vertical scale?
Usually not. In some cases, it's helpful to help people
understand the shapes. It can produce confusion, however, especially
relative to truly scaled buildings and trees. The larger the
scale of the model, the less likely you are to need exaggeration.
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26. How can we show project phases or options?
If you can define the area of special interest, we can provide
interchangeable inserts. If you must study the model first,
you can ship it back to us and have us cut a hole and fit it
with one or more inserts.
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27. How can we make revisions to our model?
The models can be carved or sanded. Although we can provide
limited quantities of thinly cut foam so that you can make small
laminated additions, we would only recommend it in very unusual
circumstances. If significant "bulldozer work" is
required you might consider using the foam as a substrate, upon
which you model with clay. Alternatively, you could return the
model (by prior arrangement) and have us cut one or more "inserts."
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28. How do you produce very deep models?
We build them up from layers of three and four inch
thick foam. This reduces material cost, reduces tool-clearance
problems, and avoids warpage due to the internal stresses that
are often present in blocks of foam. Furthermore, we don't know
of a manufacturer which routinely provides foam blocks to the
maximum size of our models.
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29. Do the laminations show on very deep models?
Yes, but they can be quite inconspicuous. On stepped models,
we put the lamination at a step. On smooth models, we use our
CNC router to cut a "pocket" into which we "inlay"
the upper layer. This inlaid lamination eliminates the "feathered
glue joint" which used to be impractical to avoid on most
deep handmade models.
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30. What dimensional constraints should we keep in
mind?
We can produce model sections up to 48" by 96,"
with a depth up to 48".
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31. I'm a designer who needs a landform model. What
do you recommend?
If you need a finished model, we recommend that you contact
a model maker who can provide a fully coordinated product. If
you only need a single-color site model, we'd be delighted to
provide one directly to you..
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13. How about showing paths?
Options depend on how well computerized the data is - whether
it's practical for us to use our CNC router.
If you like, we can treat paths very much like we treat
roads. The only difference is that the scale of the model needs
to be larger in order to make this practical for handmade models.
If you need a model at 1" = 16', for instance, we might
depress the roads by 1' (.060") and depress the paths by
4" (.020"). Please note, however that this means that
road curbs will vary in height depending on whether there is
a path adjacent to the road. Alternatively, with the CNC router,
we could engrave a very fine (maybe .015") line on one
or both sides of a path.
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32. Can you help us show property lines?
In the case of smooth models which we produce from your
computerized relief, we can superimpose vector data from a separate
2D file which you provide. This allows us to engrave such information
with an appropriate cutting tool.
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33. Can you smooth out these jagged lines that computers
used to simplify curving landforms.
We can perform some "smoothing" without any problem.
Completely eliminating that "style" may increase our
labor charge, depending on the extent of revision necessary.
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34. What do you do with "messy" contours?
When the complexity is clearly irrelevant to the use of
the model (and only adds "visual noise") we try to
reduce it a reasonable amount.
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35. Our drawing shows existing terrain, can you do
some "cut and fill" so the road doesn't look so silly?
When specifically requested, we try to roughly balance cut
and fill in a way to keep grades to realistic limits - such
as 5% for parking and 10% for roads. Note that such contours
would be approximated - only intended for better conceptual
illustration, done without detailed analysis.
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36. Doesn't such dense foam make it hard to "plant"
trees?
Although you can't simply push fine "weed" trees
into the foam, it's pretty simple to push a wire of the proper
diameter into the foam, in order to prepare a hole.
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37. Can we stop by and see your machine?
Yes, with prior arrangements made.
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39. What payment terms can we arrange?
For the first model, we require a 50% retainer and the balance
COD. After that we can gradually relax the terms toward 33%
retainer and the balance in thirty days.
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40. What kind of discounts do you give?
With our "repeat" customers, we discount our charges
according to the volume of business they give us.
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41. Our drawing is a cut, spliced and revised mess.
Do we need to redraw it or highlight the contours with a red
pencil?
Garbage in, Garbage out. Although we strive to give you
what you want, YOU have to tell us what YOU want. More complex
changes may require file changes or a marked up print. Mark
only the changes on a print or file and we change only the toolpaths
that have changed. This is the cheapest way to up rev a model
because we are only changing the toolpaths. We will prepare
a 3d"shop drawing" of the changes prior to starting.
At this stage we can usually figure out the intent of the drawing
- and, if necessary, telephone or e-mail our questions for your
clarification. The important thing is for you to be sure that
your plan is not misleading enough to cause us to make the wrong
assumptions and interpretations. Only you know the purpose of
the model, so only you can judge the degree of control which
is appropriate to exercise over the details of the landform.
Unfortunately, there's no denying that bad drawings can cause
problems which we might not be able to avoid.
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