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"Bronto-belly futures are up?! Buy! BUY!!"

If dinosaurs ruled the earth, how would it be different?

My Halloween costume is a study in the corporate dinosaur. He's still ferocious, although more so on the trading floor than on the forest floor.

It was also an excuse for me to learn some new CAD tools. The tyrannosaurus head is made from 9 FedEx boxes, laser cut, folded, and taped together into a 3D, custom mask.
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Step 1: Modeling the Dinosaur in CAD

Picture of Modeling the Dinosaur in CAD
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Every project I've ever done that involved taking a project from CAD to physical object has required multiple CAD tools. This required 3 tools (6 is you count the tools I tried but which each gave unsatisfactory results for some operation), and I even cheated on the first step by begging a really nice tyrannosaurus rex model from a friend.

In Rhino, I removed the t-rex's teeth and tongue, and cut off the head.

Step 2: Making the Panels

Picture of Making the Panels
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The real magic came from some not-yet-released Autodesk and Otherlab software that decomposes a model into pieces you can build: strips of fabric for sewing, slices to glue together, or panels to fold and attach. First, I simplified the model to a shape that was still recognizable without having too many triangles (and hence panels to assemble). I then used the paneler function, which finds a series of flat panels that can be folded (without intersecting folds) and attached together forming a skin.

A preview of this software is available at 123D.

The output is the outline of the panels, perforating marks for folding, and assembly information.
Ramzed1 year ago
what's sad is that T-Rex couldn't reach his ear hole with short arms even with that giant retro-cell phone of his.
sakimono2 years ago
Haha ,I love this work
lsrieck3 years ago
Is there a reason to be anti-corporate? How about a Lobor Union dinosaur?? He he.
Honus3 years ago
Awesome! I'll have to check out 123D for future projects. Any chance of a Mac native version in the future? I've been working on a folded Stargate helmet- sooo close to finishing.... gotta get back to work!
ewilhelm (author)  Honus3 years ago
A preview of the software is available for Mac OS here:
Honus ewilhelm3 years ago
Awesome- thanks so much! I just spent some time checking out the site and it's pretty exciting stuff. I've already got a few ideas for some of my projects. :)
It would be cool to make a 3D grid model and fill it with foam and then shape it to make a positive model for complex paper mache shells.

I showed your T Rex head to one of my co workers and we thought it would be fun to make a couple of different dino heads.

I made some progress on my helmet too-
ewilhelm (author)  Honus3 years ago
Online versions is now live here!
Honus ewilhelm3 years ago
That is so awesome and super easy to use! I'm going to have a lot of fun with this with my kids. :)
ewilhelm (author)  Honus3 years ago
We're working on 123D online, which will open it up to Mac users. To be released soon!
Honus ewilhelm3 years ago
Sweet- thanks!
a4great3 years ago
what did you use for the panels?(i may have missed it)
Card board boxes.
noel0leon3 years ago
Great stuff, Although I would add some teeth to make it even more menacing
duk2423 years ago
This is pretty cool, as for breaking it up into panels, you could also use a technique used by papercrafters.
That is, using Pepakura, to "unfold" your model into pieces (of more than one panel) and then cut/fold/glue it.
You would have trouble doing it with cardboard, but with some sort of thick card it would turn out looking much neater (without all the perforations).
You can also do paper and fibreglass resin too (like this instructable: http://www.instructables.com/id/Cardboard-Halo-3-Master-Chief-Helmet/ )
Kiteman3 years ago
I wonder - did you deliberately leave the perforations visible as some sort of artistic comment or feature?

(Personally, I would have used masking tape to glue the edges, then used more to cover the perforations before painting.)
ewilhelm (author)  Kiteman3 years ago
Good idea. Masking the perforations just slipped my mind in the rush to complete this for Halloween.
depotdevoid3 years ago
Awesome. Any chance that panel-decomposing software will be a prize in an upcoming contest?
ewilhelm (author)  depotdevoid3 years ago
Some, and maybe all, aspects of it will be free in a future version of 123D.
angelabchua3 years ago
buy! BUY! Love it!
austin3 years ago
wow that's awesome! You should make an instructable dedicated to how to use that panel software.
mikeasaurus3 years ago
Where's the shot of you chomping on someone's head at work?