Draw some outlines of a baluster as seen from the front and from the side.
Step 1: Cutting
Cut your foam baluster mold using a hotwire
Step 2: Prepare the Mold
When the hotwire cube is done cutting you'll end up with a positive and a negative mold. We'll not use the positive foam baluster at this time as we want concrete.
Step 3: Pour Foam Mold
Tape off the negative mold you just cut to prevent it from opening up due to the weight of the concrete. Once secured fill your mold with a pre-mix concrete and tap it on all sides to let air escape.
Let it sit overnight.
Step 4: Unveil Your Ornaments
When the concrete is hard enough simply remove the mold and you'll have a unique concrete ornament for pennies on the dollar.
disclaimer : The foamcuttingcube used to make this model was invented and engineered by fablab013. You should be able to recreate this model with any CNC hotwire system.