For an assignment in 24-672: DIY Design and Fabrication course at Carnegie Mellon, we were required to make a clay model of a handheld household item. I chose to do a safety razor. The process included making a paper core, filling it with expanding foam, covering that foam in modeling clay, and finally carving the clay to accomplish the final intended design.

Sketching

Process

  • Core CAD Model

  • Paper Decomposition

  • Paper Core Assembly

  • Paper Core Filled With Expanding Foam

  • Clay Covering

  • Clay Carving

Final Model

The level of detail intended made the carving very difficult, but the process was very easy, and showed why this tool is used all over the industry from soft goods to cars.

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Final Sketches
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Tensegrity Chair Model