Robot-milled foam moulds for a cast terrazzo leaf sculpture

KUKA robot milling wavy leaf relief into an EPS foam block
3D-scanned leaf model in Blender viewport
Textured 3D leaf mesh in Blender
ABB robot with hot-wire tool cutting an EPS foam block
ENCY CAM robotic module toolpath simulation on ABB robot with foam cutters
Milled EPS foam master model on the CNC bed
KUKA robot next to milled foam mould with leaf pockets
Rhino and Grasshopper layout with 83 numbered leaves on the master surface
Cut leaf shapes in an EPS foam sheet

From painted maquette to cast terrazzo. Swedish designer nioform partnered with artist Jennifer Forsberg on a cast terrazzo leaf pile. A hand-painted study was 3D-scanned, then reworked in Rhino and Grasshopper into a parametric layout of 83 individually placed leaves, each with unique orientation on the master negative.

Robotic foam milling programmed in ENCY CAD/CAM software. ENCY Robot drove the whole toolchain: roughing, semi-finishing and finishing on ABB and KUKA arms with foam ball-end and flat-end cutters up to D40. The big negative plus 83 small leaf moulds were machined from bonded EPS blocks, ready for direct casting.

Turnkey handoff to Herrljunga Terrazzo. Leaves are cast separately in their own colours, placed into marked slots inside the main negative and cast into the pile body over a lightweight core. A numbered map ships with the mould so every leaf lands where the digital layout put it.

Products and Solutions

Product

ENCY Robot: A complete offline robot programming solutionView productENCY

Applications

Robot milling
Sculpture/Stone

Industries

Die & MoldArts
Want to achieve the same?This result was achieved using ENCY Robot for programming complex robot pathsNeed a similar solution for your project?Talk to sales