I'm an architect working on a project for a museum in New York. Its a huge sculpture in a courtyard. I've been researching cutting out big faceted shapes out of eps and then assembling them on site to construct a large complex structure. The sculpture is made of a few hundred chunks, probably about 20 unique ones and 10 or so copies of each.

Does anyone have any idea what type of machines (and maybe who, preferrably in the northeast) are capable of this sort of complexity?

I think that its a 3-axis job to create these cystal-like shapes. One idea I have is to use a cnc-turntable so you can make a 2D slice and then spin the block to a predetermined angle to make the next slice.

Any advice would be appreciated

Here is an example of the type of machine that you are talking about.
http://www.dcjo.com/pff_files/MEGABLOCK.pdf

Thanks for the prompt post. Its Interesting, these Megaplot machines that have a cnc turntables are the same as those offered by Demand FoamCutting in Florida. Must be an affiliate. Any idea who's offering services with this machine somewhere near NY?

thanks again

Not a clue, I'd suggest contacting the manufacturer. They would know who they sold machines to.

I've seen other machine manufacturers on the internet, but can't recall the links.

Good luck.

Depending on the shape that you are trying to achieve you may be able to just get away with using template guides on the top and bottom of your block. The guides are cut into whatever irregular shape you want and your harp cutter runs on these much like a router bearing bit. After you have finished cutting one angle you would attach another set of templates over the first ones for your return cuts. May be worth the 90 bucks in materials to try this out to avoid the cost of the 3D model, and 3-Axis machine time.

If you have some illustrations I can run a quick mockup for you with some scrap blocks we have collecting dust.

Another consideration would be the permanency of the sculpture. Bugs & Birds love this stuff unless it is thouroughly coated and a large object might entice some climbing. There is a wide range of coatings & hardeners that can be used in and outside of the EPS for durability.

How big are the pieces, I am about a week from finishing my foam cutter.

I will be able to cut up to 10 foot length. 6.5 feet wide and 38" high.

adding a turntable is nothing. The only problem is that I am in Minnesota.

If you cant find any one, I will take a look at it. I will most likely be alot cheaper than any commercial outfit.

Do you have a picture of what you are trying to make.


Eric
jjme@comcast.net