Digital Fabrication: 16' Cow
An overview of a Digital Fabrication Sculpture project.
Sourcing a Model
For this project the client wanted large cows for outdoor installation and to maintain continuity with a line of pre existing yet smaller cows. The most cost effective solution was to 3D scan an existing cow head, enlarge it, and attach to a purchased rigged cow model.
Creating Parts for Milling
Once the model was approved we could begin the milling process. There are many strategies available but in this instance we decided to separate the cow into multiple sections and mill each one on the rotary.
Programming
Once the parts have been separated we began importing each piece into PowerMill to develop the toolpath and NC Code.
Milling
After the program was written and passed collision and singularity checks, the foam block was loaded on the rotary for milling.
Assembly
Now that all parts have been cut, we verify proper cut and fit.
Hand Finishing
With the Sculpture fully assembled, I began hand finishing detail in the eyes and hooves. I also blended any seams in preparation for the final phase of fabrication.
Surface Coating
This project will needed to be fully encapsulated in fiberglass so a layer of paper mache was applied to protect the surface detaIl from being distorted during polyester resin coating.
Armature
After fiberglass is applied and cured, the styrofoam was removed to reduce weight and to allow for the fabrication and installation of a steel armature.
Painting
Now that the cow is fully fabricated we prime the final sculpture for painting
Ready for Install
Once the paint job is approved we apply a protective coating and prepare for shipping. This cow was approximately 16'x8'x10'. We fabricated three cows using this methodology.