Couple days ago i've come up with very intresting igea of how to make soft foam dolls or whatever 3d model you have without expensive equipment. and yes they can be huge or small.
So, the idea is fairly simple. You build up layer by layer cutting them according the templates that you made.
Here is a list of equipment and materials that you are going to need
- Hot knife (the one that has hot wire and hot rod to cut, like on the picture. I didn't find it quickly so i managed to make my own out of junk)
- 3D software that you familiar with (Cinema 4D in my case)
- Projector or printer A3
- sheets of paper (240g/m2 density works good. Below this will be too soft)
- sheets of 2cm (can vary) foam rubber
- foam rubber glue (i used Dunlop K-72 glue)
- scissors and sharp knifes.
Here is a step by step explanation of how i did it with projector method cause i don't have A3 printer.
Step 1
Pick a model!
I found on web a female 3d model. It was a basic model, not very high poly, but you don't need it anyway. Right now i found a better model using free DAZ 3D software and a basic model. DAZ is a great piece of software where you can modify poses and figure, breast size etc. so im going to stick to it.
upload imageStep 2
Slice your model!
The idea is to get an outline of every 2cm(or whatever foam thickness you have) of a model, but remember, thicker foam will be less detailed but faster, so 2cm is a good choise. I made a plane object that intersects with body and makes outline anywhere i want. So by lowering the model each 2cm i am getting nice outline for template.
Step 3
Calibrate your projection!
Make a cube in a 3D software with 40cm walls and measure the image of this cube on the wall. If its off the 40cm then adjust the scale of the viewport and make it 40cm in real life)). Switch to frontal projection and recalibrate the cube. At this step you can scale your model to desired height. once you did this, switch to top projection and prepare to step 4.
Step 4
Drawing
Place you model feet on the plane and low it down for 5mm in software to get nice 1st outline of the feet. Place a paper on the wall and draw outline on paper (DRAW ONLY 1 LEG). 1st template is done! Place number 1 inside template and front facing arrow. Low down your model deeper inside the plane for 2cm and repeat the process. To keep templates alignment when you cut them, you need to make 2 vertical tubes in the legs and body about 2cm dia located near each other. Each template will have 2 circles.
Step 5
Cut
When you are done drawing, its time to cut out all templates. Cut according to the outline and make 2mm holes in the center of each circle. Nothing to tell here.
Step 6
Take template number 1 and 2 and place them one on top of another with numbers facing up or down (if you make leg/arm you dont need to make 2 sets of templates. To make left leg template should be facing up and for the right they should be facing down)
Measure the foam and cut roughly small piece. Remember, always check you a measuring the foam with the current and next level template cause the next level is bigger or another shape and you can miss the edge.
Step 7
Allign
Place 1 template with number facing up and insert 2 nails in the holes yo made earlier. they should be 90 degree to the template, otherwise the next level will owt off alignment. Penetrate the foam ad place №2 template on nails with number facing down. look at them from the side and check that they are 90 degree to template and parallel to each other. If you are making legs or hands than you can just hold it by hand but if you are making a body then you have to use small amount of glue to keep alignment.
Step 8
Cut!
Heat up your string and begin to cut guiding the outline. It's tricky to watch 2 sides at the same time but a bit practice and you will be fine. Repeat it with all layers. By using the previous template you can achieve a perfect seam. Mark foam with number and front arrow and repeat whole process using next layer. You will end up with layer pattern 1-2 2-3 3-4 4-5 5-6.... and so on. When you done, apply glue and try to connect layers as correct as possible.Here is some photos.
32 size EU (23cm)
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image uploadSo, in conclusion. This method is super flexible. you can model pvc skeleton inside 3d model and add cutout for it on each layer, ending up with very accurate model. Currently i want to make real skeleton out of styrofoam with this method and add it to a model. I have allready made 1 leg (from 1st model), 1 feet with metal wire between layers, 1 breast, and ass part. Its soft and flexible (not as silicone)
Speeking of costs. i think its possible to make 160cm doll with 100-150$
More posts to come.
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