Darth Vader’s omnipresent spirit lives on in this exciting creation by one of Redstack’s team members who made it for a friend using CNC Routing. It was delivered in its own custom made box complete with LED Lighting to highlight its sophisticated and smooth lines.
This version of Darth Vader’s head was developed by Onur Ayekin and downloaded from GrabCAD.com and the model was carved in a RenShape polyurethane modelling board.
The CNC Router, also designed and built inhouse was a 2.2Kw spindle and controlled by Mach 3. It took approximately 50 hours from concept to production, all inside the backyard workshop with only the pet dog for an occasional second opinion and a bit of a sniff.
It started with the GrabCAD.com design and then taken into Autodesk Inventor to split the bust into machinable sections. These 10 sections required a lot of material removed initially to create the basic shape. This was accomplished with a 10mm long series carbide endmill and the finished using a 6mm ball mill.
To go the next step and get the finer lines and markings, a long series 4mm ball mill was used to get to the places that the 6mm could not.
Ever so patiently, each part was milled and carved until all the parts were ready for assembly.
Assembling was the fun bit. The parts were glued together and the joints blended and smoothed out to prepare for painting.
The final silky smooth, shiny Darth Vader was 9kgs in weight, and ready to grace someone’s living room.
The perfect box was created to show off this piece, complete with LED Lighting.
The recipient of this DIY home-created and manufactured gift using CNC Routing was suitably impressed. It’s the little things that make the difference and in this case the enclosure that was created was the perfect way to finish off a great project.
Redstack support the maker’s market with CNC Routers such as the Carvey 3D Carving Machine. This great little machine is very popular for maker enthusiasts as well as for those running a small business from home because it is quiet, clean and easy to use. It has a fully enclosed frame to ensure any mess is contained on the inside and it’s easy to use with built in material settings.
So if you don’t have a workshop out the back of the property and need to keep it inside the house, it won’t bother the kids doing their homework!