This is my entry into the ShopBot Challenge and the Make it Real contest. If you like it, please rate highly and vote in both contests! With a ShopBot Router and a 3d printer in my shop, I could build more crazy items (more robots and costumes). Also, I am a member of a Nashville robotics club which could make use of the CNC router for various projects.
For scale, the room in the picture is 25' x 25'! This is a HUGE costume. Look for this costume at Dragon*con in Atlanta 2012!
Step 1: Design
Since most of the models are designed to be static with no moving parts, it takes several revisions to the parts to make mounting plates, get rid of parts that impede movement of parts, etc.
Note - Take note of the slots that plug into each other. They need to allow for the thickness of your foam material (sometimes several layers)
Once you get this all done, the parts will be ready to be cut by the CNC router (a spinning tool that is computer driven that can cut out exact parts from large sheets). The machine shop will "nest" the parts (get as many parts onto a sheet as possible which saves waste and $$).
You could cut these out by hand, but that would take FOREVER. Best to use a CNC Router for this!