case studies / Gallery
Two Statues
Digital Model (far left) – The statues start as detailed 3D digital models, allowing precise planning of proportions, pose, and features.
Rough CNC Foam Cut (second from left) – The EPS foam is cut in sections, roughly forming the body and limbs.
Hand-Finished Foam (third from left) – The sections are assembled, and hand-carving refines folds, clothing details, and facial features.
Final Pre-Foundry Statues (far right) – Fully sculpted, smooth, and ready for bronze casting. Both seated and standing poses are shown together, highlighting scale and craftsmanship.
Mary Goddard
This sculpture of Mary Goddard was expertly crafted from EPS foam, using a 3-axis CNC to achieve the initial form. Fine hand-carved detailing was added to capture lifelike textures and features. The piece was scaled from a client-supplied clay maquette, digitally scanned for precision. Finally, it was hard-coated to ensure durability and prepared for safe shipment to the client.
Material & Method: Cut from EPS foam using a 3-axis CNC for the base shape
Detailing: Hand-carved to enhance lifelike textures and features
Scaling & Accuracy: Digitally scanned and scaled from a client-supplied clay maquette
Finishing: Hard-coated for durability and prepared for shipment to the client
Prototype - Turret
This full-scale military turret prototype showcases the seamless integration of digital design, CNC machining, and expert hand craftsmanship. Created as a master model for aluminum casting, it highlights precision engineering, realistic detailing, and advanced fabrication techniques used in prototyping for defense and industrial applications.
Digital Design & CAD Modeling
The turret was engineered in SolidWorks for precise geometry, scale, and mechanical detail. 3D printed references validated form and proportion before full-scale production. Every component was optimized digitally to ensure accuracy and manufacturability.
CNC Machining of EPS Foam
Full-size components were cut from 1 lb EPS foam on a 3-axis CNC router, translating the digital model into precise physical parts. Complex curves, edges, and mechanical features were accurately produced with tight tolerances.
Hand Carving & Refinement
Skilled artisans refined the CNC-cut foam with hand carving, smoothing transitions and adding fine details. This ensured the prototype perfectly mirrored the digital model, balancing technical accuracy with realistic aesthetics.
Lost Foam Aluminum Casting Preparation
The finished foam master was prepared for lost foam aluminum casting, where molten metal replaces the foam pattern. Maintaining CNC precision and hand-finished detail was critical to producing a high-quality, fully detailed aluminum turret.
Sculptures - Ybor City, Florida
These four stunning sculptures began as highly detailed digital concepts in ZBrush, where every expression, posture, and garment fold was meticulously designed. Small 3D printed models were produced from these digital files to serve as reference guides for the full-scale production, ensuring precision from the first step.
CNC Precision & Material Work
- Carved from high-density HDU foam on a 3-axis CNC machine for exact dimensional accuracy.
- Every contour, angle, and detail was translated from the digital model to the foam master.
- CNC roughing provided a precise base, preserving material while preparing for detailed hand finishing.
Hand-Carved Details & Finishing
- Skilled hand carving refined facial features, hands, clothing folds, and intricate textures.
- Each statue was finished with a Duratec hard coat, creating a smooth, durable surface ready for mold-making.
- Attention to detail ensured that the sculptural integrity of the digital model was faithfully maintained in the full-scale master.
Foundry Preparation & Bronze Casting
- Completed foam masters served as the pattern for bronze casting at the foundry.
- Every piece was inspected for accuracy and fidelity to the original design before shipping.
- The result: a seamless transition from digital concept to full-scale bronze artwork, ready to be admired for generations.