A few weeks ago, I made a new friend named Sid. He learned that I was a mentor in the 3DEXPERIENCE Lab and wondered if I could help him CNC something. Sid is a fan of "The Boys" comic and TV show, and wanted to make Soldier Boy's shield. He's always wanted to have it as a decorative prop.
After reviewing the design, I suggested that laser cutting thin layers and then gluing them up on a curved form might be a better approach to making it. Sid agreed, so we looped in @CO to help with the laser cutting.
I built a simple form by cutting 2-by lumber into curved shapes and then screwing 1/4" plywood to them. To help with alignment, I also glued and screwed small blocks to the form. These will align with the tabs that we added to Sid's laser cut pieces.
Out in the parking garage, we donned our respirators and got to work applying contact cement to the 1/8" plywood pieces. We clamped the first piece to the form, and then attached each layer to the previous one with a bit of pressure. The immediate bond that contact cement forms is remarkable!
We gave the piece a few minutes to set up in the form, and then popped out shield so Sid could hold his creation for the first time! Needless to say, he was thrilled!
Sid is headed back to college today, so he's taking the unfinished shield with him. He'll remove the tabs, do a bit of sanding, paint it gold, and add an arm strap to the back. I can't wait to see it when it's finished! I'm sure he'll make a post when that's all done!
