We have machined the Yoda file in foam at life-size. For this process we cut the file in four separate stages on a rotary-axis enabled CNC router, the FROGMill from Streamline Automation. The tool used was a 1/4" Ball nose foam tool. This process allowed us to capture a great amount of detail in the piece.
A short video of the process is available at: http://www.youtube.com/watch?v=ODrwU1EfgdE
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