The highly productive and efficient automated milling process and Hollywood studios are taking advantage of it.

The English company Robocarv dedicated to 3d modeling, scanning and robotic sculpting with multi-surface finish. I provide a solution for creating decorative elements for a theater or television scene with a KUKA milling robot.

Making realistic-looking objects and panoramas begins with a block of sintered expanded polystyrene (EPS), which is a lightweight, easy-to-use material used by robots based on CAD drawings obtained from scanning. It is ground and then carved by a robot. The model then covers the product with polyurethane foam and other hardened resins to increase strength and create a substrate for decoration.

Compared to the time required for manual operation, it takes only a few hours to mill a sculpture like the bust of the Egyptian Queen Nefertiti with the KR Quantec robot (KR 210 L180). When it is necessary to dispose of the object, the protective layer can be removed and the polystyrene can be recovered after pressing.

Time in a film production is a primary factor and the solution with the KR Quantec milling robot from kuka recreates a figure in a few hours with a high level of quality.

To date, the largest sculpture Robocarv has produced is the 15-meter tall lion, which is the film version of the musical “Cats”.

Robocarv recycles the material after burning, then removes the protective layer and presses the foam into new blocks. What brings profitability.

Liam Carr of Robocarv said: “There will always be some accessories made by hand. But for products that are near perfect and geometrically precise, we use robotic precision.”

So in Hollywood sculptures and sets will have the latest technology in robotic milling systems to manufacture objects of the past or future, which will have a realistic appearance designed in plastic blocks.