Hired as a contractor for Sef Pinney Design, we were tasked with creating the original three master model petals which would get replicated five times each for a total of fifteen petals. The arrayed petals are suspended twenty feet in the air along the new DJ stage at the KAOS Dayclub and Nightclub at the Palms Casino Resort and Spa in Las Vegas.
We were given 3D models of each flower petal. Since there were large steel tubes that needed to fit inside the shell, it was crucial that we got the curvature and thickness correct along the entire petal. Using our CAD programs we sliced each petal into smaller pieces and constrained them in a bounding box. We cut our foam blocks into corresponding sizes to each bounding box and projected and traced the profiles of each piece on all six sides. From there we hot wired out each profile and adhered them back together, patched, sanded, and sealed them.