The 180 inch long "surface" component was constructed on Rhinoceros and milled with the use of a CNC cutter. It is the host to 55 "plugs", which were casted out of liquid resin.
20 rubber molds were formed from a 3D print of the plug. Liquid rubber was poured into the molds to cast the plugs.
The final result of the liquid resin "plug" shows a metal rod component, which helps reinforce it into the "surface".
Initial paper exploration for 3D "plug"
Originally the plugs were planned to be casted using corning foam molds. Through investigation it was found the corning foam and liquid resin would not react well together.
The final result of casting the liquid resin "plug" in corning foam molds
The plugs were casted in 4 shades of amber and strategically placed to mimic the surface's undulating curves.
The prosthetic will be installed at the URBN Center in Philadelphia, PA come January 2013. It will sit flesh into a horizontally ran I-Beam located on the first floor.
