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
The head comes apart thus to give a load of slices.
These were used to transfer to the final material - MDF (Medium Density Fibreboard).
These 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!
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...