Step 4: Transferring the design of the carved model to a different material

Picture of Transferring the design of the carved model to a different material
Once the template was ready, it could be used to transfer the pattern to another material. This is the same principle as a 3-d printer, but hand-made!

The concept was partly inspired by these awesome designs for a Buddhist temple by Heatherwick Studio.

Image: Steve Speller

Deconstructing a carved laminated headSlices through a carved polystyrene headThe head comes apart thus to give a load of slices.

These were used to transfer to the final material - MDF (Medium Density Fibreboard).

Cutting out head layersAutomata head slicesThese were then cut out of the MDF board with a jigsaw.

The centres were cut out. This was to create a cavity that the servo mechanics would occupy later.

A more accurate transfer from the model could be created using a lot more layers, each of which would need to be a lot thinner.

In theory, if the layers were thin enough, you wouldn't really need to re-carve the casing after transferring the layers. However, while this is OK in theory, in practise it would mean cutting out, lining up and gluing loads more layers.  I much prefer carving stuff, to the boredom of cutting out loads of boards!

Carved head layers recreated in MDF Here are the templates in MDF, next to the carved model. The MDF is a stepped sample. This is like using a half inch thick feed in a 3-d printer.  

Obviously this only gives the outline shape and needs recarving...