3D Spiral lollipop help

[NeathawkSigns]

Hello Im a first time poster on here!! I started a 3D sign making company and recently made a 3D tooth with a face (butt &all). After I finished and installed the teeth (3),I got a proposition to make 3D spiral lollipop for a candy store. 4 total. The "candy" part is 7 ft tall with the post it being wrapped around is roughly 4.5" wide. I have previously usedPVC to make my signs. I was thinking of using HDU for this project. It is interior and will be on direct sunlight. I was thinking of using 3inch HDU carve the exterior of the pop then turn itover and carve a half circle (where the post sits in it) and do the same on the second side. Paint the pop then glue to pole. Does this sound right to do? We have a 4x8ft shopbot. Is HDU the right material to use? Any and all suggestions appreciated.

[knight_toolworks]

I don't think hdu would be good where people can touch it.

[myxpykalix]

I am confused by your description of the spiral candy? Do you have any pictures or drawings of what you are trying to do? Are you talking about a flat spiral lollipop (the part you lick)
or are you talking about a spiral that wraps around a column similar to this picture?

[NeathawkSigns]

Attached is the type of pop we are making 7 ft.

[CNYDWW]

Looks like you'd be hard pressed to mill that on a 3 axis machine without quartering it. Doing two pieces, the sides are going to loose detail. If by chance you have a 4 axis machine and aspire, all you'd need is the 3d model and do it that way. Another option would be milling out a mold from extruded polystyrene insulation board. You can get it in 2" thickness. Biggest issue with that is finding an affordable castable material that will hold up. Not to mention weight issues. Castable resin would be the best bet for durability but it is expensive and heavy. They do however have options to add filler beads and the like. Fillers reduce weight and volume of the expensive resin.

Regards
Randy

[Brady Watson]

You sometimes have to think outside the box for a project like this. You *could* machine a couple of long strips of HDU or even plastic cast them with the rounded profile & wrap them manually onto a dowel or mandrel to get the final look you are going for. You may have to scarf the back to make them flexible enough, but with a little bondo or thickened epoxy, it's pretty straightforward.

-B

[NeathawkSigns]

The reason I was going to use HDU was because it is much lighter and I can get 2" or more thickness if I need too. I was going to epoxy the exterior halves to give it a hard shell per say, and then sand/paint. Then when I was installing glue to steel posts, epoxy the seams lightly sand and touch up paint. Attached is a drawing I did. I may just try out on 2" installation foam first.