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icon10.gif  From a Shapeways printout to a wood sculpture [message #57232] Wed, 21 November 2012 13:17 UTC Go to next message
avatar Selwy  is currently offline Selwy
Messages: 4
Registered: September 2011
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Hi Guys,

I would like to share some information about a production process I have developed this year, together with a local wood carving company (www.3dwood.com).
We already use this production pipeline daily now, because it has so many advantages– and Shapeways plays a major role! (how could it be otherwise...)
I'm going to explain the steps with the help of two models that are for sale on my website: www.ben-godi.com

1. Digital Sculpting

I use Pixologic ZBrush for sculpting. It allows me to create and sculpt the model entirely on the computer; from concept to final sculpture. I'm able to change things based on client's feedback quickly, with no need of making laborious changes on a clay model for instance.
What I have to keep in mind is, that the outcome will be a physical object and in this special case, an object made out of wood. As you already know for sure, wood consists of fibers that growth in a certain direction. Therefore it's necessary to avoid thin parts that go across that wood grain. They break easily.

http://www.ben-godi.com/project/ben-godi-emancipated-01.jpg

http://www.ben-godi.com/project/ben-godi-emancipated-02.jpg

http://www.ben-godi.com/project/ben-godi-rabbit-01.jpg

2. Preparing the model for 3D Printing

When I'm done with sculpting, I make use of ZBrush's "decimation master" plug-in and reduce the polycount. A super-highres mesh isn't necessary for printing. I use Magics RP from Materialize to combine all shells to a single shell and to fix mesh errors, in case the model has any. Removing shells is necessary for giving your sculpture a wall thickness later on. In Magics RP I also perforate the sculpture, so the dispensable powder can be removed after printing.

http://www.ben-godi.com/project/ben-godi-magics.jpg

3. Prototype and Production 3D printing

For production on the pantograph (see point 4 below) you need to work on a reference model that is at least twice as big as the final wood figurine.
That's necessary for transferring all the small details to the wood and makes it a lot easier to work with, because you must trace the surface by hand on the profiling machine later on.
But before I order the big printout for production, I go for a small version, ideally the size the final wood sculptures will be, to see how the model looks as a physical object.
Whenever I feel something doesn't look right, I go back to ZBrush and try to fix it (composition, balance...)
Shapeways Sandstone material is fantastic for printing prototype models – it's really affordable and looks great. For production, I go for Strong and Flexible with a wall thickness of 1.5 mm.
These models are pretty big, up to a total height of 50 cm and sometimes more.

http://www.ben-godi.com/project/ben-godi-prototype-printing.jpg

http://www.ben-godi.com/project/ben-godi-production-printing.jpg

4. Production on the Pantograph (3d profiling machine)

I fill the double sized plastic 3D printout with a special resin and mount it on a metal plate. Everything has to be assembled very strong to prevent it from bending or changing its position during tracing on the machine.
The tracing itself isn't an automated process yet; you still have to do it by hand. And you have to be super careful. Oh boy, in a moment of carelessness you ruin the whole row of figures!
You start with some bigger milling heads for rough machining and switch to the smaller once for detailing. I use maple wood for my work. It doesn't change its color over the years and allows very fine details.

http://www.ben-godi.com/project/ben-godi-production-milling.jpg

5. Finishing and Refining

The figures that come straight from the pantograph look great but aren't finished yet. It needs a lot of sandpaper work to smooth the surface.
I add details with my set of small carving knifes and boost the once that disappear during milling. Finally I paint the parts I want to be painted and add a thin layer of wax that prevents the wood from getting dirty.

http://www.ben-godi.com/project/ben-godi-finishing.jpg

6. The final product

If you keep an eye on some production restrictions, (wood as a living material, the dimensions the pantograph allows, avoiding spots that are difficult to reach with the milling heads...), the possibilities are endless!

http://www.ben-godi.com/project/ben-godi-emancipated.jpg

http://www.ben-godi.com/project/ben-godi-not-your-rabbit.jpg

For more information, please feel free to visit:

www.ben-godi.com

www.selwy.com
www.3dwood.com
www.pixologic.com

Kind regards,
Ben

[Updated on: Fri, 30 November 2012 16:52 UTC] by Moderator


www.ben-godi.com www.selwy.com
Re: From a Shapeways printout to a wood sculpture [message #57234 is a reply to message #57232 ] Wed, 21 November 2012 13:50 UTC Go to previous messageGo to next message
avatar kevinweinewyork  is currently offline kevinweinewyork
Messages: 23
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Hey Ben, awesome post!
Re: From a Shapeways printout to a wood sculpture [message #57243 is a reply to message #57232 ] Wed, 21 November 2012 17:25 UTC Go to previous messageGo to next message
avatar DarioScapittaDesign  is currently offline DarioScapittaDesign
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Just amazing!... lovely!


Dario Scapitta Design
www.darioscapittadesign.com
Re: From a Shapeways printout to a wood sculpture [message #57244 is a reply to message #57232 ] Wed, 21 November 2012 18:09 UTC Go to previous messageGo to next message
avatar natalia  is currently offline natalia
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Wow this is so cool.
Fantastic post! Thank you for sharing!


Shapeways Community Manager
Re: From a Shapeways printout to a wood sculpture [message #57246 is a reply to message #57232 ] Wed, 21 November 2012 20:03 UTC Go to previous messageGo to next message
avatar Piers  is currently offline Piers
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Thanks for posting that great job


formerly known as pdb
icon14.gif  Re: From a Shapeways printout to a wood sculpture [message #57256 is a reply to message #57232 ] Thu, 22 November 2012 02:20 UTC Go to previous messageGo to next message
avatar Fairesure  is currently offline Fairesure
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Just awesome! Shocked
Re: From a Shapeways printout to a wood sculpture [message #57264 is a reply to message #57232 ] Thu, 22 November 2012 07:50 UTC Go to previous messageGo to next message
avatar Selwy  is currently offline Selwy
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Hey guys,

Thank you very much! I'm really glad you like it.
I think the whole process can be further optimized and enhanced. We are still at the beginning Cool

Cheers,
Ben


www.ben-godi.com www.selwy.com
Re: From a Shapeways printout to a wood sculpture [message #57265 is a reply to message #57264 ] Thu, 22 November 2012 09:36 UTC Go to previous messageGo to next message
avatar Vidalcris  is currently offline Vidalcris
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Omg this is awesome work ! Congrats Razz


Re: From a Shapeways printout to a wood sculpture [message #57267 is a reply to message #57265 ] Thu, 22 November 2012 10:36 UTC Go to previous messageGo to next message
avatar MitchellJetten  is currently offline MitchellJetten
Messages: 802
Registered: June 2011
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Please do show more Ben!

Love your work!


Kind regards,

Mitchell Jetten
Customer Service Coordinator
Shapeways
Re: From a Shapeways printout to a wood sculpture [message #57268 is a reply to message #57232 ] Thu, 22 November 2012 11:08 UTC Go to previous messageGo to next message
avatar mygadgetlife  is currently offline mygadgetlife
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Registered: January 2012
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Wow, this is amazing!

Thanks for sharing!


mygadgetlife.blogspot.co.uk
Re: From a Shapeways printout to a wood sculpture [message #57311 is a reply to message #57232 ] Fri, 23 November 2012 08:56 UTC Go to previous messageGo to next message
avatar macouno  is currently offline macouno
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Registered: April 2008
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That's great work!

I wonder... is there a similar sort of technique you could use to also scale your work up? I've been thinking of having some of my stuff done in "life size bronze" for instance.
Re: From a Shapeways printout to a wood sculpture [message #57380 is a reply to message #57311 ] Sat, 24 November 2012 13:04 UTC Go to previous messageGo to next message
avatar Selwy  is currently offline Selwy
Messages: 4
Registered: September 2011
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Junior Member
Guys,

Once again, thank you very much for your comments. That really means a lot to me!
A big THANK YOU goes to Mitchell for his great support during the last 12 months! Cool

@macouno: Yes, there is a way to scale up a model and make a life-size statue out of it. You would have to produce the piece with a KUKA robot for instance. You can also use different materials; it doesn't have to be wood. I sculpted a bust of a local politician last year and 3dWood brought it to life with their robot: http://www.selwy.com/2012/cnc-milling-the-human-head/

This one didn't made it to the profiling machine... It's available on my shapeways shop: http://www.shapeways.com/shops/selwy

http://www.selwy.com/ben-godi-cowgirl.jpg

Have a great weekend!
Cheers,
Ben


www.ben-godi.com www.selwy.com
Re: From a Shapeways printout to a wood sculpture [message #57399 is a reply to message #57232 ] Sun, 25 November 2012 00:35 UTC Go to previous messageGo to next message
avatar lensman  is currently offline lensman
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Man, it's your ZBrush modeling that blows me away, quite apart from the rest of this. Do you by any chance haunt the ZBrush Central forums and have any modeling tutorials, etc? If not, you absolutely should. This stuff would go over like crazy there!

Glenn


Glenn ------ My Website Third Dimension Jewellery
Re: From a Shapeways printout to a wood sculpture [message #57400 is a reply to message #57232 ] Sun, 25 November 2012 00:35 UTC Go to previous messageGo to next message
avatar lensman  is currently offline lensman
Messages: 1656
Registered: December 2009
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Shapie Expert
Man, it's your ZBrush modeling that blows me away, quite apart from the rest of this. Do you by any chance haunt the ZBrush Central forums and have any modeling tutorials, etc? If not, you absolutely should. This stuff would go over like crazy there!

Glenn


Glenn ------ My Website Third Dimension Jewellery
Re: From a Shapeways printout to a wood sculpture [message #57406 is a reply to message #57400 ] Sun, 25 November 2012 07:13 UTC Go to previous messageGo to next message
avatar denali3ddesign  is currently offline denali3ddesign
Messages: 563
Registered: February 2011
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Senior Member
Agreed, your modeling is top notch Ben - mind blown!

Thank you for sharing.


Pssst! I wrote a book to help you quickly get your Sketchup models ready for printing. Click here to get it on Amazon
Re: From a Shapeways printout to a wood sculpture [message #57754 is a reply to message #57232 ] Fri, 30 November 2012 17:32 UTC Go to previous message
avatar natalia  is currently offline natalia
Messages: 875
Registered: September 2008
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Hi Ben,

I couldn't keep this to myself, so I posted your fantastic tutorial on our blog!

http://www.shapeways.com/blog/archives/1800-3D-Printing-rein vigorating-wood-sculpture.html

Hope you like it!

Best,
Natalia


Shapeways Community Manager

 
   
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