I tried to edit my post above with no effect. #113. It got cut off due to a bad character I think. this is how it should read.
It's Renshape 5020 or 5025. There are different densities. As bishop said, those boards can run between $850-$1200 depending on the market.
As far as writing the code for it, I couldn't imagine actually writing it manually. Just not possible. We use a program called RhinoCAM to generate the toolpathing. There are other programs out there as well from the ever-popular Mastercam to more affordable like deskproto.
A one click solution would be nice, but the biggest challenges when setting up a CNC milling file are the fixtures, tools and finish. For example, the helmet needed over 4" to fit half of it. Depending on the length of the tool being used we only have about 5-6" of vertical travel. And that is with a 6" x 1/2" ball endmill. But a 1/2"ball leaves a 1/4" radius over all the details and just skips anything less than 1/2". So lets use a 1/4"Ball, now this endmill is only 3" long and the part is over 4", so how do we get to the features we want without crashing the spindle into everything? This is where fixture comes in. How do you hold the part in place? In this case Bishop machined down to the subplate and removed the excess foam for collision. So as long as there are no steep walls over 2.5" he will be fine. Things get even more tricky when you are going to do a two-sided part.
I did not path this, Bishop has pathed all the new parts and has done a good job at it.
If you didn't guess it, I work with Bishop and am one of the 2 halo fan modelers that he had mentioned. I was on these boards in the past as xes or xesxes. not sure.
-also I have been after him to mold that rifle for some time now. It was sad to see it sitting on a shelf collecting dust for so long... Glad to say that it is now dust free, what his plans are at this point I don't know.
