Theatre Design & Technology - Winter 2017 - 40

ABOVE: 123D Make includes a feature for step-by-step assembly.
This tool was essential for constructing the full scale piece.
LEFT: The statue was assembled in sections for stability.
Scaffolding was built below Apollo where the the two figures had
not yet merged.
Photos by Michael Thomas Driggers.

The process was fairly straightforward, and the experience with the scale model provided prior knowledge
of where to expect trouble spots and where to plan for
scaffolding support. The team was also fortunate enough
to have a sculpture student working in the scene shop at
the time, and that student really had a strong grasp on
how the more ambiguous appendages would assemble
separately and attach to the larger composition.
That being said, 123D Make was indispensable for
assembly. The software includes a step-by-step assembly
tab that breaks down each layer into its respective pieces
and shows the user how each part should be oriented
with respect to the one below it. Another advantage of
engraving the labels produced by 123D Make is an obvious up-orientation for each piece as well as the fact
that each label faces the same direction. While it seems
simple, these features help speed up the assembly process and eliminate a lot of potential user error. All in all,
the assembly took the better part of a month to complete from start to finish.
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As we placed the final pieces, we began to notice
that the faces of the two figures seemed to be lacking
the desired level of detail. While they were assembled
correctly, the resolution that stacks of one-quarter-inch
MDF provided simply was insufficient for such a highly
detailed and familiar form. Prop Shop Manager Tim
Jones suggested using a 3D Printer for these sections.
Because the entire project originated as a digital object,
this idea of 3D printing seemed like a great solution to
achieve the desired detail. After considering making a
type of mask for the figures that could be placed over
the MDF, the team decided that simply cutting away
the faces and replacing them would be a cleaner method. After choosing a few specific places where it would
be easiest to make the cuts, the faces were isolated in
Meshmixer. The new plastic faces were printed using a
Makerbot Replicator. The entire process was very successful, and the same technique was used to print both
of Daphne's hands and Apollo's outstretched foot.
SMOOTHING THE EDGES
With the base of the structure complete, the team
turned its attention to smoothing the ridges and giving
the statue its finished marble appearance. We considered sanding away the sharp edge of the MDF layers to
limit the amount of filling that would be required, but
this would shrink the entire form, and the corners of
each layer really helped define the shape of the statue.
Scenic Charge Coordinator Ann Chismar sampled a
variety of materials for the covering process, includ-

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