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.
Step 1: Modeling the Dinosaur in CAD
In Rhino, I removed the t-rex's teeth and tongue, and cut off the head.
Step 2: Making the Panels
A preview of this software is available at 123D.
The output is the outline of the panels, perforating marks for folding, and assembly information.
Step 3: Cutting the Panels
On our 75-watt Epilog laser cutter, I used 75% speed 100% power for the outlines, 90% speed 100% power for the perforations, and 100% speed 8% power for the markings.
In the images, only the second one shows panels (actually the cardboard scrap) that were used in the mask. Images 3 through 6 shows panels I didn't use because they were too small to manipulate (62 total panels versus 22 total panels for the same-sized model). Snapping the too-small panels out of their cardboard sheets kept a two-year occupied for a little while.
All of my panels are attached, should you be inspired to make this yourself!
Step 4: Fold, Tape, and Assemble
Step 5: Paint and Make Eyes
Step 6: Do Some High-Powered Dino-Deals
From inside the dinosaur mask, I can only see out the mouth, which leads to the amusing feature of the corporate dinosaur always pointing directly at what he's looking at.