This project was created as a part of Carnegie Mellon's DIY Design and Manufacturing course in Spring 2023. The point of the project was to to learn how to make a 3D mockup of a product using expanding foam and modeling clay. Something that is commonly used in some industries. I decided to make a 3d mockup of a rocket. I went with this object because I find space craft interesting.
I started off with creating many different design sketches of possible options before settling on a desk space craft model. With my concept and design selected I then created a simple model of the design and laser cut out a paper mold. This I would use to create the core foam part of the model. I made sure to clear out the bottom so that I could pour the foam easily into all the corners
With my mold complete I then mixed the 2 part expanding foam together and pored it into my mold. I waited a few hours for the foam to completely set before trimming off the excess.
With my foam core complete I then created a detailed sketch of the features I wanted on the final model before taking the modeling clay and heating it up and shaping it onto the foam core
The main criteria for this project was to take a detailed 2d sketch and create it out of foam and modeling clay. I was able to get the basic shape and larger details on my 3d model. However I over estimated the amount of smaller details I would transfer from paper to 3d in the time given.
Overall, I am happy with out the model turned out and think it gives a good approximation of the 2d sketch.
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