I happen to have quite a bit of experience working on full-bodied car patterns. Of course the method of machining totally depends on your budget, but I used to work with a Haas VB-1 bridge mill (200”x84”x40”) that was awesome for cutting dense foam and renshape patterns. This machine was also robust enough to machine aluminum tools when required. Haas made very few of these machines, and there are still a few floating around on the open market. Depending on the scope of your project, it may be more cost effective to outsource your pattern making…just a thought.
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