Brady Watson
02-07-2012, 10:51 AM
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/RonaldBrownUSUN-1.jpg
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/Seal2.jpg
Last year I had the privilege to work on the Great Seal of the United States for the newly built Ronald H. Brown U.S. Mission to the United Nations Building in NYC.
My part in the process involved laser scanning an approved foundry pattern, and then rebuilding parts that were worn or needed some added detail. Major areas included rebuilding the prismatic stars on the Glory, removing and rebuilding the lettering on the marquees, plus digitally sculpting minute dings, dents and scratches present on the original pattern. The relief was then scaled up to the specified 84" overall diameter.
Due to the scale of the parts, each element was broken out and nested on a single 4X8X3" sheet of Duna HDU, with a 2D profile strategy. Breaking the model up in this way allowed me to gain more control over the 3D machining process. Each part was registered to a 1/16" outline scored right into the spoilboard. This matched up perfectly with my 3D Roughing & Finishing passes. Parts were held down to the table with carpet tape. Most parts were machined with a super extra long 3/16" ball end mill, but some, like the lettering on the marquee, required me to go back in those areas to sharpen up with a 1/16" ball.
Overall, I think that it took about a week to machine everything, including the 3" backer disc. Overall thickness is just under 6". Parts were then packed up and sent out to be bronze coated and assembled, before being installed in December 2011.
-B
Some pics are a little washed out because the building has a glass roof.
Original Pattern:
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/OriginalSeal.jpg
Scanned Data (Before Rebuild):
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/ScannedResult.jpg
...more pics below...
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/Seal2.jpg
Last year I had the privilege to work on the Great Seal of the United States for the newly built Ronald H. Brown U.S. Mission to the United Nations Building in NYC.
My part in the process involved laser scanning an approved foundry pattern, and then rebuilding parts that were worn or needed some added detail. Major areas included rebuilding the prismatic stars on the Glory, removing and rebuilding the lettering on the marquees, plus digitally sculpting minute dings, dents and scratches present on the original pattern. The relief was then scaled up to the specified 84" overall diameter.
Due to the scale of the parts, each element was broken out and nested on a single 4X8X3" sheet of Duna HDU, with a 2D profile strategy. Breaking the model up in this way allowed me to gain more control over the 3D machining process. Each part was registered to a 1/16" outline scored right into the spoilboard. This matched up perfectly with my 3D Roughing & Finishing passes. Parts were held down to the table with carpet tape. Most parts were machined with a super extra long 3/16" ball end mill, but some, like the lettering on the marquee, required me to go back in those areas to sharpen up with a 1/16" ball.
Overall, I think that it took about a week to machine everything, including the 3" backer disc. Overall thickness is just under 6". Parts were then packed up and sent out to be bronze coated and assembled, before being installed in December 2011.
-B
Some pics are a little washed out because the building has a glass roof.
Original Pattern:
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/OriginalSeal.jpg
Scanned Data (Before Rebuild):
http://i772.photobucket.com/albums/yy8/braidmeister/Great%20Seal%20of%20the%20United%20States/ScannedResult.jpg
...more pics below...