kostas georgiouclay + alias portfolio

Based in Newcastle UK.

kostas.georgiou@icloud.commobile phone:07577850890

Currently Studying Transportation Design at Northumbria University. 2010- 2014

(Graduation on 15th July ‘14)

Xenophya Design- July 2013 till PresentInternship 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.

Continued internship for the duration of my final year at Northumbria University, working on my Final Major

project.

Aeon Sportscars 3 months 2012Tasked 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 Com-plete KitCar. There is a 4 page spread on my work.

Alanco Agricultural- 2 months 2012I was set to re-design the cabin of the Sprayranger 300D

Model Alanco Currently makes. My design will be in produc-tion in 2013.

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

EDUCATION EXPERIENCE

SKILLS

INTERNSHIP - 4 MONTHSxenophyadesign

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!

Redbull Soapbox

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.

Working from CAD

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 or-ganising! 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 pos-sible. 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.

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 Mould-

ing and Hard Modelling.

REDBULL SOAPBOX RACE

INTERNSHIP - 3 MONTHSSportscars

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.

Prototype Build

INITIAL SKETCH-Initial Sketch work

AEON GT3 ALIAS MODEL

I created the presentation visuals using Autodesk Alias to present before modelling commenced.

Rendered in Luxion KeyShot 4

Presentation Visuals

AEON GT3 ALIAS MODEL

hard model buildSportscars

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.

Hard Model Prototype

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.

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.

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.

Plotting the Windshield

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 mas-sively 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 mid-section.

I fashioned a detail in the front of the footwell, just under the windshield

mount for the wiper unit.

Making the Screen Surround

The roof had to be made in a higher position, on the buck to allow for more headroom, the biggest chal-

lenge 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 fibre-

glass matting, applied the resin and when it was dry, the roof was skinned in body filler.

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.

Spraying the Buck

foam modellingv engine8

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.

QUICK FOAM MODELLING

final year modelall terrain vehicle

My final year model is currently underway and I have designed an ATV for the Indian market place that creates platform for develop-

ment 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.

Scale Clay Model

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.

Alias model - chassis

My model is a half scale quad, do finding and sourcing handlebars was immediately an issue. I created the handlebars using Solid-works 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.

Solidworks to a solid model

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.

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.

Building the Armature

WORK IN PROGRESS

Thank you for taking the time to look through my portfolio, I hope to hear from you soon.

Kind regards,Kostas.

Thank You

mob. 07577850890email. kostas.georgiou@icloud.com

Kostas Georgiou