We were recently requested to provide a medical company with models for a conference and exhibition in Portugal. Their logo is a weaver bird,so as a centre piece for their exhibition they required 5 model weaver birds to hang from an artificial tree. Our designers drew the bird in CAD, which we were able to use to rapid prototype a master bird from SLS.

The master modelwas rubbed down to create a smooth surface finish then used to create a silicone mould. This mould was then used to make 5 more birds from polyurethane “fast cast”, a liquid mixture which sets hard in less than ten minutes. This process was used as it is cost effective, and meant could keep to the tight deadline of just over one week.

Our model-makers created the legs and feet from sturdy welding rod which was inserted into the main body to provide stability. The birds were then finished using a combination of hand and airbrushing techniques to achieve the realistic feathered effect. Wire hoops were interwoven with green dyed weaving wicker to create the birds nest, inserting artificial foliage to maintain a realistic appearance.

Once the birds were inserted into the nests their feet were wrapped with wire to keep them upright. Ensuring the models arrive safely to their destination is key, packing each bird and nest securely before they left our premises to travel to Europe.