Zumbiel Packaging 3D Flat

[Jesse6669]

I need a flat of Zumbiel Packaging for my Z scale shelf layout.  Here's the prototype seen in the background of the photos:





Zumbiel is a curtain-wall building, the typical old factory of a concrete frame filled with brick walls;  Zumbiel is an amalgamation of older factory sections and a newer addition--I'm probably just going to freelance model the older factory sections to keep it simpler; The old part also has a water tank which was removed sometime in the 80s, but I want to model because it's emblazoned with "Zumbiel Boxes". 

I designed a test 3D printed wall section with a frame of the concrete sections, and openings for brick/window inserts.  These wall section (or variants) can then be linked together to make the structure as long as needed, with angle pieces that can be inserted to allow for corners of various angles.   My plan is to use brick cardstock from Archistories--although I could 3D print the sections with brick texture then paint or decal them...  But the brick stock seems easier;  I'm testing 3D printing the windows but as thin as they are, they tend to curl a bit.  They could be etched. 

Here's the initial test sections. 

[Jesse6669]

I made a couple larger test sections, and the design is about 80% done.  There are two sections to the plant-- an older section with the water tower (on the left), where I believe the manufacturing floor was.  The right hand side on the rendering is the newer section, which I believe was offices and warehouse space.   Still to be done are some interesting exterior details seen in the pics, including a truck dock, some stacks and what I think is a cyclone dust collector. 


The walls are modular so they can be easily printed on my Sonic Mini 8k.  The sections plug together with interlocking pegs/holes.  There's a foundation strip that the main walls plug into so the building can be removed from the layout if needed.I'm waiting on the brick paper to test the "curtain" assembly-- brick paper will be cut to fit and glued to the blocks that fit into the concrete frame.  Windows are printed into the frame and will be backed with thin clear plastic (transparency film for presentations).  The new test print validates the windows can be printed without curling. 

[Scottl]

Very cool.  Do you print them flat or at an angle? 

[Jesse6669]

Very cool.  Do you print them flat or at an angle?

These were printed flat, with the wall "inside" being the bottom with supports.  There's always some of that sagging on the back, but the front is dead flat.  I support the window mullions as well.  I rarely print at an angle, most of the time layer lines aren't visible--I'm printing at 40 micron layers btw, although this printer will go down to 20.   

[cgw277]

The entire structure looks very nice, but those windows are outstanding! To my eye, they look perfect, can't detect any sagging. Thanks for showing us what is possible with resin  printing.
Scot

[Jesse6669]

Making progress on the various modular components of the "old" building.  Just a few more panels to be printed on the water tank section.  This is a dry fit to see how it goes together.  The brick sheet should be arriving this week. 

[Jesse6669]

I received a couple sheets of Archistories Z scale brick.. amazing stuff!  It's embossed really thin..paper?  wood?  Anyway--it's beautiful brick sheet.  So to test out the concept of applying the brick to the inserts--the curtains on the curtain wall--I cut out a section and glued to the 3D printed insert and slid into place.

I'm pretty happy with this. 


Next, to test the color of the concrete; I want to use something out of the bottle to make any later touch-ups easier.  Tamiya Buff and Vallejo Deck Tan are the two colors I eyeballed as close to a concrete color.  I brushed them on a piece to test.  Actually, they both seem ok compared to some pics, but the buff is a bit too red I think.  The pic where Buff is a close match was taken in morning sun, casting a red hue.  The Deck Tan seems a bit too light, but does have a cooler, greyish hue vs the Buff.  I think with a dark wash/weathering it'll look right.

 

[Lemosteam]

Which Tamia number can are you using?  I use AS-16 for anything concrete.  Try a can- I think you will like it.







I used White, mixed white+sepia india ink for my mortar lines. It's water based bush on and quickly wipe excess off the painted brick.  It does seam to weather the brick face a bit:

Brownish Red brick:
 

Grey brick:

[Jesse6669]

John, the Tamiya is XF-57 iirc.. I'll check out the spray but I have the Vallejo deck tan on-hand and it looks ok.  It's also easier to airbrush acrylics vs. rattle can for me.  I'm not going to try doing mortar.. This is Z remember!  Plus I think the material is more porous and wouldn't let the mortar flow in like a painted plastic would.  Might test it though!

Test of the Vallejo Deck Tan on a wall section-- This is airbrushed on.  I painted the section of windows with an AK Interactive paint pen (love them) and glazed with some clear overhead presentation film.



I just ordered some Z scale fence and a Kibri "factory detail kit" that contains a bunch of ductwork, pipes, tanks, etc.  I could 3D print but that'll save a bunch of time.

[Scottl]

I agree, the AK pens are excellent.  Really nice work, as always.

[Jesse6669]

The plan is to print some curtain sections with windows/doors/louvers in-situ, then cut the brick stock to fit around it.  I wanted to test this out in practice using a scrap piece.  I like how it turned out, there are several seams but not very visible and certainly close to the variation found in real brickwork.  The brick stock handles really well.  Even where some "bricks" fell off--it looks like prototypical spalling.  I applied the brick using thinned PVA (Krystal Klear).   






   

[Jesse6669]

I've been printing more sections of the Zumbiel factory between other projects.  It's slowly coming along and it's nearly time to start assembly. 

Here's a mock-up with a rendering edited into a photo of the location.  This iteration still has the water tank on it.  The tank was removed in the 80's and I'm going to omit it since it really overpowers the scene (the top of the water tower would be flush with the top of the backdrop).  I also removed a couple sections that would've made it too long for the space allocated.   


This is the "modern" version of the factory.  The peaked roof with the white ends is where the water tank was located.


And here are the framework components test assembled.  I'm going to ACC these sections together first.  Seams will be puttied, then the whole of it painted concrete.  After that there will be the brick "curtain" sections to add.  Also note the truck loading dock which is a separate piece.  There will be a dust removal system (I believe that's what it is) added towards the left of the building as well.  I'm still designing this machinery.

[Jesse6669]

Test fit with the truck dock.   
   


Below is test fitting the brick panels on the old building section, which required a good bit of sanding to fit.  Any more of this I gotta wear the PPE--this created a lot of resin dust even with wet sanding!  These blocks will get a veneer of Archistories brick as tested earlier.
 
Note there are small foundation pieces along the bottom of the walls, and these will be attached to the layout.  They have holes indexed to pegs on the bottom of of the walls and the idea is the building will clip into these foundation slabs and be removable to service the track or add lighting, etc. 



Soon, I'm going to need to ballast the spur and add the pavement where the track approaches and enters the building.  Debating whether to just use styrene or use Sculptamold/modeling clay.   

[Jesse6669]

I made this dust collection system for the plant.  There's piping that will go up onto the roof.  This is vastly simplified compared to the prototype but I think it gives the right impression.  Incidentally, I think it's for cyclonic dust collection, or perhaps for small paper or vinyl scrap bits that are trimmed.  Not 100% sure. 



Here it is test fit, along with the truck dock.


Soon the main building frame will be getting roofs, the parapets along the edge of the roofs, and sanding/filling and painting.

[Jesse6669]

I made progress filling in the brick curtain sections.  These are individually 3D printed, then a piece of Archistories brick paper is cut to fit and glued on with PVA (Krystal Klear).  I also put a wash of thinned PVA over the outside to keep the edges of the paper intact, since the little individual bricks sometimes fall off (although this itself just looks like spalling).  Once dried, I test fit and when needed a light sanding on the sides with 320 grit paper until it's a slide-in fit.  The sandwich of paper/3D printed backer sands together nicely. 



Here's the panels test-fit so some are a bit off kilter.  The seams on the window sections should be less noticeable with weathering.



I'm going to be doing a bit more filling/sanding on the primed frame before painting with my concrete formula, then installing the brick panels.  Windows will be masked off and painted silver.  The new section (on the right) has large sheets of brick paper that will attach to the grid, with a few small 3D blocks like the older section.

It's starting to come together.