The idea is to cut your model into slices and cut cardboard with the shape of your model slices. When staking the slices in the correct order you get your model in rough finish to start sanding.
The final model will have really good weight and resistance. A great advantage of this method it's its precision since the model comes out almost exact as the 3d computer model. A disadvantage is the amount of time you may spend cutting and sanding.
This is kind of a replacement for a laser cutter and MDF plaques. For me it was faster and more controlable than laser cutting MDF. Hope it helps!
In dedication to my design classmates with whom I learned this technique. | Dedicado a mis compa�eros de dise�o con quienes aprendi y sigo perfeccionando la tecnica.
Step 1: Make Your 3d Model
I use Rhinoceros 4.0.
Step 2: Slice Your Model
Rhino has a special tool to slice your model in any direction you like. Just type "_Contour" and hit enter to start the tool. Make sure "grouping objects by cutting plane" is on so all the curves of each slice are grouped togheter.
In the second example shown I have chosen to slice the model in a diagonal direction. This tool only creates curves, it doesn't really cut your model so don't worry about your model being cut.
Keep in mind that the thinner your slices are, the thinner and easier to cut your cardboard will be BUT you'll have more slices to cut. You'll also get more exact models with thinner cardboard. It all depends on what you'll do and what results are you looking for.
Step 3: Print Your Slices
You can print them on regular paper or on sticky paper so you can forget about adding glue later.
Step 4: Cut Your Slices
(The first picture shown is of the handle of the gardening spoon, didn't take pictures of this part of the process for the saw. The second photo is of a handle of a screwdriver a classmate of mine was making.)
Step 5: Glue Your Slices Togheter
Unstick the paper before you glue your cardboard parts together.
Apply the glue with a big brush so it applies evenly. It is important to apply glue evenly in the borders of each slice so you can sand worryless later.
Press and let dry for a few hours.
Step 6: Sand, Add Plastic Putty, Sand, Paint, Finish
I recommend you apply some primer before you paint to even the surface.
Practice a few times because it's a technique that gets better with it. Share your experimentations with others. Thanks for reading and the best of luck!