The more things change, the more it seems we're drawn to places that connect us to the past. Whether it's as lofty as a church cathedral or as everyday as an office building, the architecture of days gone by has the power to remind us of where we came from.
Maintaining links with the past through architecture has always been a labor of love. Restoring a building that has seen better days or recreating the feel of an historical building has traditionally involved tedious, manual processes hampered by high costs, extensive labor and the potential for inaccuracies. But the times are changing. The development of advanced foam cutting and 3d foam carving technologies has introduced a world of new possibilities for restoring and revisiting traditional architecture.
Gaining acceptance as a lightweight, easy-to-install, cost effective replacement for traditional building materials, foam is now used to create a range of architectural features, from columns and balusters to moldings and other decorative features. These pieces can be made with foam and then coated with materials that stand up to the elements, or foam can be used to create molds for concrete, cast stone, plaster and a range of other materials. Despite this, there has been some hesitation to adopt this material for traditional building and architectural restoration. While concerns about introducing new technology into a field full of tradition may be partly to blame, the technologies available in the past simply haven't been up to the task.
The introduction and integration of a number of technologies, including 3D laser scanning, 3D foam milling and innovative mold making processes is solving these problems and making foam carving a perfect option for architectural reproduction and restoration. Dwayne Lehman, president of Streamline Automation, a company that has pioneered the use of these technologies, explains that they "essentially eliminate the problems that come with traditional methods, whether it's the amount of labor involved or the inaccuracies. They provide an automated solution that's more efficient and accurate than anything available before."
The process starts with the original architecture, whether it's the existing original, a photograph or even a memory. Where an original piece exists, the object is laser scanned to create a digital file that's accurate to within thousandths of an inch. If the original is long gone, a digital file can be created using 3D modeling software to bring the past to life. In both cases, the resulting file can be edited and adapted within the software to ensure accuracy and detail. In cases where restoration work is required, the software can be used to correct the effects of time. As Lehman explains, "this is really where history and technology come together. This system lets you bring architecture back to its original form."
Once the data file has been prepared, it's sent to a 3D foam router, which can recreate the piece in exacting detail using high density foam. Depending on the nature of the piece and how it will be used, there are a number of options at this point. For less intricate pieces, a positive version can be milled out of foam and then coated to produce a sturdy final product. In cases where the final product will be created using cast stone, concrete, plaster or a range of other materials, new mold making processes allow a detailed mold to be created from either a negative or positive version of the piece. These molds are then used to create the final product.
Lehman explains that the benefits of combining foam cutting and carving technology with innovative mold making processes "go beyond the most obvious time and labor savings. It can recreate and restore with great accuracy, but it also brings new flexibility and efficiency. Architectural designs can be stored digitally and then altered, scaled or added to as required. So it's not only about perfect restorations, but it's also about allowing new uses of traditional architecture in modern building."
The end result is accurate and authentic reproductions and restorations that are almost impossible to distinguish from original versions. The process brings improvements to traditional processes but still creates end products that capture the spirit and craftsmanship of the originals. So while this is a technology that's moving traditional building forward, it's also letting us maintain our connection to the past.
For more information about integrated foam carving systems and about Streamline Automation's FROG3D foam cutting and carving system, visit http://www.3dcutting.com
Streamline Automation's FROG3D" foam carving system helps creative businesses from around the world create stunning concrete molds, architectural features and themed environments with unmatched speed, detail and accuracy. Streamline's clients not only get automated, end-to-end production processes, but they can also increase their production capabilities, boost their creative freedom and expand their businesses. Streamline Automation also provides a range of business-building services developed specifically for the concrete and sculptural industries. These services are designed to deliver the knowledge, skills and operational processes our clients need to grow their businesses around FROG3D" - whether they are industry newcomers or seasoned veterans.
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