Making a Cardboard Head With a Secret Hiding Spot

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Introduction: Making a Cardboard Head With a Secret Hiding Spot

We made a box in the shape of my son’s head.  We laser cut pieces of taskboard (corrugated cardboard works well, too) and laminated them together. The heads pivots on a dowel and is held in place by two magnets

Step 1: Taking the Photographs

We started by taking a series of photographs. We used software called 123D Catch to turn the photographs into a 3D model.

Step 2: Making a Polygonal Model

123D Catch made a polygonal mesh from the photos. Here's a screenshot of the mesh 

Step 3: Turning a Polygonal Model Into a Solid Model

We then turned the polygonal model into NURBS surface so we could do some further modelling operations

Step 4:

We then modeled an elliptical cavity for the hding spot and put in holes that would be used for alignment, for the pivot and for the magnets.

Step 5: Slicing the Model

We then used 123 Make to slice the model. It's important to measure the material accurately in telling the software how thick to make the slices; otherwise the final model will come out distorted

Step 6: Assembling the Head

Then we laser cut all 212 parts and began assembling the pieces. We just added layer after layer and used yellow glue (white glue works just as well) to put them together.

Step 7: Using a Dowel As the Pivot

A dowel pin is inserted and used so the head can pivot open.

Step 8: Adding the Magnets

Round magnets have been added on the top and bottom of the head so it snaps close and conceals the secret hiding spot

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    Plz send file me.saeed9164033320@gmail.com

    Olá,
    Tenho uma Router CNC, e gostaria muito de fazer esta cabeça fatiada em MDF de 2mm ou 3mm.
    Por favor, alguem poderia me fornecer este arquivo em DXF ou DWG ou CDR ?
    Ficarei muito grato.
    joao.souza@rizon.com.br

    amazing i wonder if i could do this with a knife

    Yes, you could. It would take a while as you wouldn't have the automation of the cutter mentioned, but it could be done!

    Agreed -- you could do it with an exacto knife but it would be a labor of love. There are also a bunch of srvices where you can send the files and they'll cut it for you

    What services? How much would it cost USD? I do not have a laser cutter (and I know how many cuts that would take with an xacto - no thank you)