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Chris has described it correctly in principle. In practice, it takes quite a bit of, well, practice--on both ends: getting the drawings right, then fine-tuning the laser to successfully generate the masters. You can create a surprising amount of depth this way, assuming the right materials and techniques are employed. As it happens, a school bus is ideally suited for the process as the overall form is blissfully devoid of large, compound curves. The body is comprised of about 33 flat parts assembled to create the full form.
An actual product is better than no product... so I'm just curious: Since the laser causes a "layering" effect similar to cheap rapid prototyping, why not just draw the bus in 3D and have Shapeways produce it? It could be hallow then...Or spend the bucks on a Perfactory or FineLines master for casting with virtually no visible layering.I can appreciate all the time invested and the back and forth with trying to complete this with a laser... but it probably ate up the ~$200 an excellant RP master would have cost, no?
Dunno I think this looks better than RP:http://www.nztproducts.com/images/tbs_z02b.jpgAnd it might be harder to smooth out a whole RP piece at once.
No. Granted, there's almost always a number of solutions to a given problem; I chose to use those skills and techniques with which I am most familiar. If I was really proficient at 3D rendering, I might have done this with Shapeways. But I can draw laser cutting art in my sleep. The bus took perhaps a cumulative total of a couple of days to draw, with three iterations of revisions, and less than a day to assemble the master. The larger block of time (the span of a few months) was spent honing the technique principally for other purposes: the bus is just part of a much, much larger project (to be launched by the end of the year by Stonebridge Models) that involved a lot of seriously complex 3D laser cutting which could have easily consumed months of 3D drawing time (even if one was proficient), but instead took only weeks to draw as flat art. When you see this product line, you'll hopefully realize that the laser was the right choice.
I hasten to add that the project to which I referred was conceived, developed and executed entirely by Karin at Stonebridge. My bus (and a few other goodies) just came along for the ride, so to speak--I slipped my art into the workstream, and voila. NZT will be doing the casting work for the new Stonebridge line.