Enlarging Sculpture- foam carving, Magic Sculpt, needle felting

– [Steve] So today I’m gonna talk a little bit about this
large scale project. Basically, I’m going from this piece here which is about eight inches tall, to this piece here that
is about five feet tall. The original piece was
done in Super Sculpey, then I took a silicone mold of that, and then I cast it in resin. First thing had to do was get a high quality scan of the original sculpture. I spent a little bit of time researching 3D scanners to figure out if this was something that I could do on my own, but I came to the conclusion that basically the time and money that I would have to spend on
it just wasn’t worth it. So I farmed it up to this
company called Scan Site. The scanner they use is
a white light scanner the sculpture is placed on a table, and then the scanner collects data points via projecting a grid of lights on top. This piece was scanned about 18 different times in different positions. Each scan collects about
five million points of data. Then all of the scans are consolidated and one final rendering is created. So the scan costs about $200, but I ran this piece through
with four other pieces, so if you do them in bulk, you definitely get a price break. A large part of what you’re paying for is the initial setup, so while one piece might cost you $500, if you run five of the pieces through, they might cost you 200 each. The next step is to take the scan to the foam carving company. You tell them how large
you want the piece, and the plug those numbers
into a computer that runs a super large five axis milling machine. These foam milling guys work in a lot of different industries. A lot of times, they’re enlarging small scale sculptures
that will eventually become life sized bronze statues. With this process, they’ll
enlarge the piece out of foam, and then a sculptor will
go on top of that with an oil clay and work in all the detail, then they’ll take that to the foundry, they’ll take a mold of
that, pour it in wax, and end up casting it in bronze. They also work in the
entertainment industry doing sets and large scale props, and with museums and theme parks doing large scale
dinosaurs and clown heads. Coolest thing about this process is you can get super large
pieces that are very lightweight. A lot of the times, these pieces will just be finished with a super hard shell that’s just sprayed on. So very to paint and
finish and very durable. There’s several different foams that you can get your piece milled out of. This is the white bead foam. This is the foam that you
see all over the place. It is just compressed beads. This is a two pound right here. This right here’s a three pound, it’s a little bit denser. But you can see that it’s still
the same compressed beads. The benefit of this foam is that it’s the cheapest. It is about five dollars per a cubic foot. It’s also the most lightweight, which is kinda nice. The downside of this foam, it doesn’t really carve that well. If you’ve ever played
around with bead foam, you’re really just getting
all these little loose beads, so it’s hard to get any nice detail if you need to go in there
and carve on your piece. Another disadvantage of this foam for what I’m doing, I use this Magic-Sculpt
on top of the piece which is a hard epoxy. It doesn’t really stick to this surface because it’s very smooth, so the Magic-Sculpt
just kind of peels off. This next foam is a blue EPS foam. The EPS stands for expanded polystyrene. This is the foam that I get
all of my pieces done in. It is a little bit more expensive than the white bead foam. This is about five dollars per cubic foot. There’s a couple reasons
why I prefer this foam. This is a two pound density. It’s basically just a block of foam that has chemically expanded
and formed one solid piece. So it is very easy to
come in here and cut. Come in here and file. This big rasp is one of
the main tools that I use when shaping the foam, so it’s very easy to carve the foam and get the exact shape that you want. This material, it’s a
closed cell structure here, so it creates this kind of texture so the Magic-Sculpt will stick to it. It is a little bit heavier
than the white foam, but it’s still pretty lightweight. So the third foam that most places have is this stuff right here. This is super dense. You can carve into it and
get really nice detail. You see this stuff used a lot in the product design industry, in the automotive industry, mainly because of the
crazy detail you can get. This a lot more expensive
than the other two foams. This is about $35 per cubic foot. One thing I don’t like about this is that if you file or sand it, it creates this super fine dust that is impossible to get rid of, and it’s super itchy. I got some in my eye once and I had to use an eye wash about twenty
times to get it out. I took a shower about 30 minutes ago, and after this video
I will go take another one just because I’m touching this stuff. So I had two pieces
made with the EPS foam. The one on the left is five feet, the one on the right is four feet. The five foot piece cost
me 15 hundred dollars. The four foot guy, I think about $800. If you look, picked up
quite a bit of the detail, but not all of it. I could’ve paid more
money and had him go back with another pass and really get in and flush out the exact detail. I don’t need to do that because I’m covering this with the Magic-Sculpt, so really I told him that I
just need the basic shape, so it’s less work for him, saved me a little money in the long run. So in the next video, I will be going over applying the Magic-Sculpt on top, sculpting in the texture, and then priming the piece, and then finishing it with a
variety of different paints. (upbeat music)

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