p PAGE 17SUMMER 2011
As the name suggests, automated foam carving is a technology that automatically carves or sculpts using foam. It combines the light weight and ease of manipulation of foam, a perfect medium for carving and sculpting, with advanced technology that can automatically sculpt virtually any object in absolutely any size. This automation comes about thanks to the integration of a number of technologies that work together to translate sculptural concepts and models into digital format and then bring them to life using advanced carving machinery. Automated foam carving’s core technologies include 3D laser scanning, design and editing software, 3D CNC hot wire foam cutting and 3D CNC foam routing. Together, these technologies create an integrated process that commonly follows these steps:
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Design - The starting point for automated foam carving is the same as a conventional sculpting process, an artist creating a sculpture, maquette or model. Whether this is done by hand or through the use of digital sculpting technologies, the sculptor retains full control over the artistic process.
3D Laser Scanning - When a physical sculpture or maquette is the starting point, 3D scanning allows for the piece to be scanned and captured in a digital file with minute detail. This process brings physical objects into the digital world with very little effort.
Editing & Toolpathing – Once a sculptor’s work is captured digitally, the resulting file can be edited and adapted on-the-fly without rework to the original. With editing complete, software automatically carries out a process
called toolpathing which translates the digital model into instructions for CNC (computer numeric controlled) production machinery. CNC technology essentially translates the shapes and lines of an object into something that a machine can understand and recreate.
CNC Cutting & Carving – Once complete, the toolpathing file is sent along to the machinery that will produce the piece. While simple, linear- based shapes can be created using a CNC hot wire foam cutting machine, the true workhorse of automated foam carving is the 3D CNC foam router. Using router bits specially designed for foam, these machines can create virtually any organic shape or design with perfect accuracy and detail. For larger projects, a process called ‘blocking’ automatically breaks the project into pieces that can then be assembled.
The end result of this process is a perfect foam replication or enlargement of the initial model – created in a fraction of the time of conventional methods. This foam version can now act as a foundation for the artist to complete the creative process, either with coating, painting and finishing, or with casting and molding.
THE START TO A PERFECT FINISH For projects like themed environments, props, advertising projects and exhibits, the foam is typically coated and finished. Thanks to specialized foam coatings and spraying equipment, this process creates an end product that, while foam on the interior, can stand up to virtually any kind of conditions or treatment. Once coated, projects can then be finished to exact specifications with a range of painting and finishing techniques, some of which can
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