Tech EXPO 2017 Figure 3 - The finished statue in production (Courtesy Utah Shakespeare Festival, Karl Hugh Photographer) transferred into Aspire, the computer-aided manufacturing (CAM) software used to write instructions for the CNC router. Using Aspire's suite of 3D modeling tools, the shop staff was able to scale the model to the size the designer required and slice the model into machinable sizes. Given that we had to sculpt the front and back of the statue, the model was split along its center line. The back was inverted within the software to remove undercuts and then front and back were sliced into 2" thick sections which could be individually carved from 2" expanded polystyrene foam. These sections were processed for 3D carving in the software and then exported to the CNC router for carving. The carved slices were adhered together using 70NF contact adhesive and the resulting rough sculpture was an adequate starting point for the scenic artist (Figure 1). The limitations of our CNC router made some of the features difficult to carve, most notably the ears. To achieve these details in the finished product, the scenic artist used clay and images of the actor to enhance cer- tain features and details that were lost in the 3D capture and carving process (Figure 2). The finished piece was a stunning replica of the actor and seamlessly integrated into the production (Figure 3). The time required for this project was also minimal in comparison to more traditional methods. Capturing and carving the initial base took about two days and the scenic charge was able to finish the sculpting while overseeing the painting of the rest of the scenery over the course of about a week. It is estimated that using this approach saved about 20 hours overall within the project compared to more traditional methods. If you factor the total reduction of work placed onto the scenic charge and the accuracy of the reproduction, there were additional savings which are more difficult to quantify. Biennial Theatre Technology Exhibit 2017 21