Also; I'm entering this build in the 3D Printing Contest. If you like it please vote (up there in the top right corner) I would LOVE to win a 3D printer - holy smokes, how awesome would that be????!
Here are the materials that I remember using:
SLS 3D printing
Wood (3/4 ply, 2x4)
5/8 threaded rod
Spray paints and primers
Smooth-on Mold Star 30
The first step in the build was figuring out what it would look like. I scratched out some possible shapes and designs in my sketchbook and ran them by the production designer. As it turned out he was taken with one of the doodles and we went ahead with that design without changing it too much (mostly the antlers and the addition of a rocket jet pack on it's back). I hired a 3D renderer (Brad Rothwell, who has submitted some great stuff here on Instructables) to make a Solid Works rendering that I could submit to the printers.
Step 1: Building the Legs and Substructure of the Torso
After a lot of growling and mumbling by me we ended getting just the head done, using a 3D process called SLS from a company called Anubis. I have to say, I was really happy with the results. While still considerably cost-prohibitive for projects that could be done by hand with sculpting (the bill for the head was just under $600), the result was actually really great. I'll get back to this in a bit.
We printed the wire frame of the sketch at the size and I glued pieces onto 5/8 ply, cut them out with a scroll saw. Tina cut out the padded armor pieces from mdf and glued them onto the legs.
The torso was a shaped piece of 2x4 (we needed this to plug the legs and neck into later). Tina glued foam onto the 2x4 and shaped it by comparing it to the printout.
Step 2: Apoxie Sculpt! Amazing Stuff!
Anyway, we covered the legs and torso in it and then Tina went to town shaping it (she's much better than I am at sculpting). She just kept comparing the piece to the printout, then to the opposite leg, and just kept working at it until they looked manufactured. I was quite impressed, if I may say so.
We joked that the torso looked like a cooked concrete chicken. Eventually that's all I could see, a chicken torso.
Step 3: Molding the Nose, Painting the Legs.
I hit the legs up with a light coat of primer, gave them a smooth sanding and then a considerably thicker coat of glass brown. The trick now is to let them sit for almost two days without touching them (fingerprints!!!).
Step 4: Finishing
I glued the 9V battery pack to the inside of the head. I had forgotten to request a lip along the seam and structural gussets inside the head rendering so the piece, which is only about 1 mm thick, was tough but pretty wobbly/flimsy. I ended up sculpting a lip to be able to glue the jaw and upper head together. I also made a 'brain' out of three pieces of layered plywood. This gave me something to drill the neck into and added some rigidity to the skull.
Step 5: Finished!!