Bringing Darth Vader Back to Life with CNC Routing and Autodesk CAM

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 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.

This is how the project evolved:

It started with the 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.

darth vader cnc routing


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.


darth vader cnc routing


Assembling was the fun bit. The parts were glued together and the joints blended and smoothed out to prepare for painting.


darth vader cnc router


The final silky smooth, shiny Darth Vader was 9kgs in weight, and ready to grace someone’s living room.


darth vader cnc router


The perfect box was created to show off this piece, complete with LED Lighting.


darth vader cnc routing


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!

Call Redstack on 1300 667 263 or +61 8 8360 7000 to discuss our range of 3D Design software, 3D printers and CNC Routers or visit our online store.


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