This tutorial describes the various steps taken by Derek to create his model of the Cyborg Sensation Vehicle (C.S.V.) project. It’s a 1/4 scale model with 1100×550x330mm wide, and it was made in Umea Institute of Design within 6 weeks.
The methods used in the modeling process go from CNC milling to 3D printing, among others techniques for a better finish.

The Development

1. It was made an IGES File to consider an effective cutting way on the complex form of the C.S.V., by using a CNC machine milling.

2. High density hard foam was milled with CNC machine to get a raw shape of the exterior parts.

3. A wood base structure was arranged to attach the exterior parts together. This structure has also an important role to assemble the interior components.

4. The gaps formed by the joins of the exterior parts were filled up with putty.

5. A lot of sanding was done to obtain a clean surface.

6. Liquid putty (green color in the photo) was sprayed on the hard foam to fill small holes and to check the surfaces quality.

7.The canopy window was shaped using Vacuum forming. The material is a transparent acrylic with 2mm thick. It wasn’t an easy job. The first one broke when the acrylic was cooled down too quickly.

8. Afterwards, the canopy window was sprayed with smoke (transparent grey) color on the inside surface.

9. Small parts are 3D printed with a Rapid Prototyping Machine.

10. Then it was made a sanding and spray prime on the parts.

11. Laser cutting machine was used to make the wheels spokes. It’s a transparent acrylic with 6mm wide.

12. An Airbrush was used to spray a base silver color and then the surface was sprayed again with a clean coat to give a better finish.

13. For the final photo, a light box was placed above the model to get a nice reflection on the body surface.

The Result

14. The attention for details makes the difference.

15. A closer view of the driver seat.

16. Front wheel and artificial muscles.

17. As a result, a shiny model with exquisite details and smooth surfaces.

I hope this tutorial was useful for those who didn’t know how a model is made nowadays. Well, for me it was enjoyable to learn a little bit more about model manufacturing. And all this was possible thanks to Derek who had the pleasure to give us information about his Cyborg Sensation Vehicle model development.

Many thanks to Derek ;)

Check out his blog for more projects http://derekchikkinng.blogspot.com/