In 2008 My father and I were commissioned to create a 14' high monument of a cougar for Washinton State University. We also created three smaller sized bronze replicas of the monument to sell to alumni and fans.
In this instructable I will show you how I created a monument and three smaller sized replica bronze editions using ZBrush and the latest rapidprototyping technology. This was my first experience with this process and perhaps the first time this entire process has ever been used in this way!
You will learn about the lost wax process, ZBrush, CNC machines, scanners, 3d printers, SLA machines, and much more. I hope you enjoy. You can view the project at cougarpride.com
In this instructable I will show you how I created a monument and three smaller sized replica bronze editions using ZBrush and the latest rapidprototyping technology. This was my first experience with this process and perhaps the first time this entire process has ever been used in this way!
You will learn about the lost wax process, ZBrush, CNC machines, scanners, 3d printers, SLA machines, and much more. I hope you enjoy. You can view the project at cougarpride.com
Remove these ads by
Signing UpStep 1: Materials and Equipment
This Instructable is quite involved and has many phases or work.
Shown here is are the general tools, materials, software and equipment used in the process. This is not a comprehensive list, but some of the most important items are itemized.
Clay tools
These tools were used in creating the monument.
1. Clay - 2AB-225 Plasticine Oil Clay - a very nice blend that does not casue irritation under your fingernails
2. Detail tools - Richeson Double Wire End Tools - This is merely my choice here but any similar tools can be used.
3. Curved Rake - These are to even out large smooth areas.
And of course you thumb and finger for lots of handwork!
Equipment
Here is the equipment used in creating the replicas, however, Zbrush was used in creating the original sculpture.
1. Zbrush, Modo and Rhino
2. Scanner - Atos
3. 3d Printer - Objet 250
4. Sla Machine - Viper Pro
There was additional harware specific software used as well.
Hard Surface Tools
These materials are used to cleanup the objet and viper models which have build lines and sometimes need minor correction.
1. Filler - Adtech P-14 - a high grade filler. One can use standard body filler as well but this is nice stuff.
2. Surfacer - SEM Flexible Primer Surfacer. This is thinner than the filler and great for filling holes and smaller cracks.
3. Pallete knife - great for small mixes and application of filler and surfacer
4. Die Grider - Harbor frieght cheapy, but works great
5. Ruby and diamond bits - they run very clean and smooth.
6. Abrasive Paper - Mirka Abranet - very nice to use
7. Wax - Ferris Patch-Eze - really, nearly any kind of wax can be used to fill pinholes.
8. Wax tools - helps to press the wax into holes.
9. Mixing Board - Clean Sheets - mulitple paper sheets are great to mix filler on.
Shown here is are the general tools, materials, software and equipment used in the process. This is not a comprehensive list, but some of the most important items are itemized.
Clay tools
These tools were used in creating the monument.
1. Clay - 2AB-225 Plasticine Oil Clay - a very nice blend that does not casue irritation under your fingernails
2. Detail tools - Richeson Double Wire End Tools - This is merely my choice here but any similar tools can be used.
3. Curved Rake - These are to even out large smooth areas.
And of course you thumb and finger for lots of handwork!
Equipment
Here is the equipment used in creating the replicas, however, Zbrush was used in creating the original sculpture.
1. Zbrush, Modo and Rhino
2. Scanner - Atos
3. 3d Printer - Objet 250
4. Sla Machine - Viper Pro
There was additional harware specific software used as well.
Hard Surface Tools
These materials are used to cleanup the objet and viper models which have build lines and sometimes need minor correction.
1. Filler - Adtech P-14 - a high grade filler. One can use standard body filler as well but this is nice stuff.
2. Surfacer - SEM Flexible Primer Surfacer. This is thinner than the filler and great for filling holes and smaller cracks.
3. Pallete knife - great for small mixes and application of filler and surfacer
4. Die Grider - Harbor frieght cheapy, but works great
5. Ruby and diamond bits - they run very clean and smooth.
6. Abrasive Paper - Mirka Abranet - very nice to use
7. Wax - Ferris Patch-Eze - really, nearly any kind of wax can be used to fill pinholes.
8. Wax tools - helps to press the wax into holes.
9. Mixing Board - Clean Sheets - mulitple paper sheets are great to mix filler on.
Visit Our Store »
Go Pro Today »
Go Cougs!
Sculpture (model) in zbush can be slice w/ section?
Thanks for sharing,
Cheers,
Phil
Baking with a UV light might work if it was a laser-cure resin process, but it wouldn't work for a hot extrusion/deposition or laser sintering process.
I think there might be two different substrates used in the process, one that cures and one that doesn't (support) maybe that is the issue. If so, perhaps your suggestion would not help.
This is how I am using the terminology: http://www.finelineprototyping.com/intro/technologies.php
i've been getting some of my models 3d printed via shapeways.. its definitely a great feeling seeing something you've sculpted in actual physical form.
i did a bronze casting(lost wax process)elective in art school(7-8yrs back)..created a handfull of bronze creatures.., so have always appreciated the work that went into making these large monuments.. never thought it had got this technologically advanced though!
have you tried sculptris? its a lightweight and free app thats great for sculpting(pixologic the makers of zbrush own it now..but have still kept it free)
ps: small typo: please correct "Marquette" to "Maquette"
Thanks for the spell check...English was my weakest subject:)
only spotted yours because i googled it .. (had heard it used before and was wondering what it meant)
Sorry, I guess some of us stay 8 yrs old on the inside :-D
Sucks to be low man on the totem pole..."hey Jimmy, get in the cougar's butt"
What was the contract amount?
Regards
.
Tony
It is quite like a cartoon.
And... it looks like he is high on chew. Terrible!
There is NO comparison. You have done a beautiful job!!!!
My wife says: "Go Cougs"
signed,
Jerry, arch rival, Husky.
Excellent job!
Jerry
Obviously I know that there are professionals doing this (and many other things), but I really didn't expect one of them to share the whole experience with us. Hope others get inspired by you and we get more from professionals to complement and give ideas to the poor DIY mortals :)
Thanks a lot!
Were there any issues casting the SLA model? I know from experience that sometimes the resins used don't burn out completely leaving an ash residue in the cavity that can affect the casting.