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Beyond Design, Inc.
Little Shop of Horrors - Road Show
Theater
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Audrey Head
Making Parts
Theater
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Little Shop of Horrors
Making Parts
Foam Core Creation - In this mold, we applied about ½” of 2 pound urethane spray foam and sanded the interior to a smooth surface. This created a one piece, double curving core section that was critical to the light weight of the final part. Thru the elimination of core seams, less carbon fiber was needed to achieve the required strength.
Epoxy/Carbon Fiber Composite- On the prepared foam surface we laminated a layer of 5.7 ounce carbon fiber cloth with epoxy resin. Once the parts were cured we assembled the mold and connected the parts with a layer of carbon fiber and epoxy. Once complete we de-molded the foam and sanded the exterior. On this surface we laminated another layer of carbon fiber with epoxy.
Final Part - This created an extremely strong and light-weight foam-cored composite. When complete the new jaw weighed a little less than 30 pounds and was much easier for the puppeteers to handle.