What
- Engineered a life-size lion sculpture divided into modular segments that serve as a sacrificial or reusable mould for concrete casting.
- Developed a multi-part assembly with interlocking alignment tabs and registration markers so the form can be rebuilt accurately.
How
- Segmented the complex organic mesh into smaller components, each sized to fit standard FDM print volumes.
- Added structural flanges and connector pins to hold seam alignment and resist the hydrostatic pressure of wet concrete during the pour.
Results
- Delivered a scalable route to heavy concrete statuary from lightweight printed masters.
- Optimised shell thickness to minimise material use while keeping the rigidity needed for casting.
Tools and processes: Mesh segmentation, mould and formwork design, large-format FDM printing, concrete casting