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.
For this project, a photograph of Yoda (the version from the Empire Strikes Back) was used as reference for digitally sculpting the character.
The head was the starting point for the Yoda model.
Next the hands and feet were modeled. In this case, the same base shape was used for all four appendages.
The hands and feet were placed onto a basic body shape and posed.
The cloak and walking stick were created and further posing was undertaken to resemble the pose in the photo. The source photo was of a puppet sitting without the operator (Frank Oz), so some liberties were taken.
Prior to sending the model for prototyping, a base was created. The base is shelled to be more efficient with material and features a debossed title on the front, and a signature on the back. The prototype model stands ~5" (125 mm) high.
This short video of the project is also available on YouTube here.
For the next stage, we will be producing a life-size version of Yoda in foam.
Guan Yu was deified as early as the Sui Dynasty and is still being worshiped by Chinese people today, especially in southern China. He is respected as the epitome of loyalty and righteousness.
The original piece was approximately 30" (750 MM) tall.
Criteria Systems is proud of all of the Canadian athletes for a job well done at the recent Winter Olympic Games in Vancouver.
Special congratulations go to the Canada 1 Bobsled team of Lyndon Rush, David Bisset, Lascelles Brown, and Chris Le Bihan who took bronze on the treacherous Whistler track. The second-last sled out of the gate, the team came within a mere 0.01 seconds from maintaining his hold on second place and a silver medal, instead winning bronze. The bronze broke a 46-year-drought in the four-man event for Canada and capped a three-medal performance for the bobsled team at the Vancouver Games.
When your project requires large format machined part(s) we can help. Criteria Systems has access to a first-class, in-house machining facility designed to meet customers manufacturing needs. Criteria Systems CNC capabilities include EPS Foam hot wire cutting, 3-Axis CNC routers, rotational milling capability up to 8' diameter and more. With these systems, foam prototyping offers a great method for bringing your projects to life. Criteria Systems uses Streamline Automation's FROG3DTM system for foam prototyping. Integration of our 3D scanning capability and 3D CAD/CAM software means that virtually anything can be produced.
Our rapid prototyping output is great for producing smaller-scale products and scale models-while foam prototyping can be used to create incredibly large models and products.
Other uses of our CNC foam prototyping system are:
Foam Prototyping
Props
Signage
Enlargement
Point of Sale / Tradeshow Displays
Architectural Elements
Bronze/Metal Casting Plugs
Packaging
Molds for Concrete / Vacuum forming and other materials
Through our industry partners we can also coordinate polyurethane or polyurea hardcoat, painted finishing and more. Our technology is best suited for Expanded Polystyrene (EPS) machining, but we can also complete prototypes in urethane foams, polyisocyanurate foams, wood, plastics and other materials.
We have recently uploaded some new videos of 3D scans captured using our innovative new scanning technology. This 3D scanning system gives us complete water-tight meshes with incredible detail and resolution. The system is ideal for digital archiving, reverse engineering, digitizing and much more. Stay tuned to Criteria Systems as we continue to break new ground in the field of 3D scanning and 3D scanning applications.
As with all of our scans, these models can be reproduced or reduced in size using our rapid prototyping system, or they can be enlarged for large format CNC production.
3D Scanning and Rapid Prototyping at Criteria Systems are outstanding tools for medical applications.
For instance, The Walter Reed Army Medical Center in Washington, D.C. is using 3D rapid prototyping to create multi-color physical models of anatomy to aid in performing delicate surgeries.
Beginning with CT scans or photos, the institution’s 3D Medical Applications Center transforms them into 3D files, applies any color to the resulting digital models, and then uses a 3D printer to produce multicolor physical models. These models can be held in the hand and examined from all angles, which helps surgeons get a better idea of what issues they will need to know about during surgery. Currently, the center prints several of these models per week.
In particular, neurosurgeons have found the models useful as they make models of aneurysms and arterio-venous malformations to help them perform delicate surgeries. This way, surgeons report that they can know in advance the anatomical structures of the patient rather than discovering them after the incision is made, thus lessening the possibility of blood loss and chances of infections.
For orthopedic use, surgeons created a model for removal of bony growths on a patient’s knee. Surgeons used a 3D printer to print a white model of the joint with blood vessels illuminated in red and nerves in yellow, which gives the surgeon a roadmap to figure out the best route to address the tumors.
In one case, the surgeon used a sterile bag to transport his model into the operating room. He aligned his cutting instrument on the model, then aligned his instrument on the patient in the same manner.
For constructing facial prosthetic models, a 3D printed mask is used in anaplastology to avoid the process of plaster on patients’ faces used to produce a moulage casting.
Our rapid prototyping output is great for producing smaller-scale products and scale models-while foam prototyping can be used to create incredibly large models and products. 
