Click a link
above (in the second row) to see a photo essay about how the
sculptures are made.
My process is essentially to do all the heavy lifting within
the unlimited space of the computer. I use several different
programs to do this, but the main workhorse is SketchUp Pro.
I unfold the 3d designs inside the virtual space, then use
VectorWorks to clean up and make any modifications to the
unfolded 2d pattern. Then this pattern is sent to a laser
cutting job shop, where it is cut from whatever material I
decide on. I then re-fold and assemble the 2d shapes back
into the 3d form using a TiG welder. Depending on the
material, I then put some kind of protective finish, patina,
or overcoat on the final piece.
Since initially building this site, I've expanded my toolset
by incorporating both FormZ and Maxwell Render. FormZ is a
beast of a modeling program - I'm pretty sure there isn't
anything you can't model with it's expansive set of features.
Most useful to me is the Unfold tool, which allows one-click
unfolding of solid geometry. Saves me hours. Maxwell Render
is, in my opinion, the best render engine available at this
time.