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This huge piece of almost two and a half tons has been created from an original sculpture by Victor Ochoa and his impression was made by the Catalan BCN3D+, a 3D printer designed and manufactured in BCN3D Technologies, a section of the ‘ Fundació CIM ‘.
For printing the various layers of the structure first we need to digitizing their 3D design, which is made in STL (Stereo Lithography) format for later pass it on to GCode, the format the printer can read and interpret the file. In this format we will fix the coordinates with which the three axes (X, Y, Z) of the machine will work in order to print the piece.
Undo, as specialists in 3D printing and responsible for the distribution of BCN3D+ printers, has been the company leading the project and responsible to print all parts. It has enjoyed the cooperation of AsorCAD, specializing in 3D digitizing, reverse engineering and processing 3D point clouds digitized company.
Undo, with whom AstorCAD has been collaborating for ten years, has been responsible for optimize the mesh, providing thickness to the skin of the sculpture and divide all plates that compose all the sculpture, along with Victor Ochoa, designer of the sculpture. The manufacturing process of this sculpture has been enormously complex, so it has been necessary to coordinate several teams simultaneously, each responsible for performing a different part of the work.
The work begins with a 3D digitized of the original sculpture with which the STL file is obtained, with which the BCN3D+ printers work, to start the treatment of the resulting mesh. The STL file is converted then to 3D CAD semi-automatically with WRAP Geomagic software. It thickens the skin and the resulting work anchors among other plates are designed with Geomagic software, Design X, thus achieving 3D CAD file on which the inner frame is designed.
The sculpture was divided into different sections and sub-sections until they reach a suitable size to be printed by the BCN3D+ machine used during the manufacturing process. In total more than 2,900 pieces are assembled and anchored to an aluminum frame to provide stability to sculpture. Once they assembled the pieces they applied to them different surface finishes in order to protect the piece and give the desired color and texture to it.
After a pre-assembly held in Madrid, the sculpture was moved to Montreal where, once assembled, received the finishing touches and finishes on the stage of the opera.
During the performances the actors were walking above the sculpture, thus proving the strength and quality of the printing. The sculpture hangs from the top and over the course of the play the character of Elektra rotates the sculpture showing it to the audience from all angles.
For the realization of this sculpture they have needed seven months of work and a total of 100 people in the different teams participating in the project phases.
From BCN3D Technologies we are proud that ten of our BCN3D+ printers were chosen for this process, whose production was held for five months continuously, resulting this an unequivocal proof of the optimal operation and performance of our printers.