Making a Cardboard Head With a Secret Hiding Spot

We made a box in the shape of my son’s head. We laser cut pieces of taskboard (corrugated cardboard works well, too) and laminated them together. The heads pivots on a dowel and is held in place by two magnets

Step 1: Taking the Photographs

We started by taking a series of photographs. We used software called 123D Catch to turn the photographs into a 3D model.

Step 2: Making a Polygonal Model

123D Catch made a polygonal mesh from the photos. Here's a screenshot of the mesh

Step 3: Turning a Polygonal Model Into a Solid Model

We then turned the polygonal model into NURBS surface so we could do some further modelling operations

Step 4:

We then modeled an elliptical cavity for the hding spot and put in holes that would be used for alignment, for the pivot and for the magnets.

Step 5: Slicing the Model

We then used 123 Make to slice the model. It's important to measure the material accurately in telling the software how thick to make the slices; otherwise the final model will come out distorted

Step 6: Assembling the Head

Then we laser cut all 212 parts and began assembling the pieces. We just added layer after layer and used yellow glue (white glue works just as well) to put them together.