To create the part, Sally and Vince (technicians at London Bronze Casting) 3D scanned Bill using a photogrammetry technique. The data was then manipulated in a variety of CAD programs to produce a final digital finish and look.

What I really like about the Green Man Project, is that it brings a digital aspect to a very analogue statue. It uses a traditional method of casting, but it’s using the very latest technology to create it.

James Reeves, Managing Director UKvoxeljet AG

The figure of Bill carries two cast impellers (a rotor used to increase the pressure and flow of a fluid), a fitting reminder of the products that were formerly made on the site.

The 3D model was digitally split into the casting sections and 3D printed in PMMA on an industrial 3D printer VX1000 PPB printer at our manufacturing facility in Milton Keynes, UK. PMMA is an acrylic material used in lost wax casting process. The PMMA print sections were then invested in a ceramic shell and cast in bronze.

3D printed bronze statue from voxeljet

The form itself was printed and then processed at London Bronze Casting, a foundry focused on research, innovation and craft to produce the final statue standing 2.2m tall and weighing 200kg.

After the assembly, welding & metalwork, a green patina was applied to transform the brown tone of the raw cast into a vivid Verdigris, a colour that all foundry workers turn by the end of a working day. Bill is the first ever PMMA-cast public sculpture in the UK.

It’s a great moment for foundry in the art industry and design world, because artists and designers are quite curious about new technologies and they’re using computer aided designs and sculpting software more than ever before. Artists can collect and scan 3D objects and manipulate them like no other material without limits. voxeljet are very diligent and have a lot of time for us, just that noticing of what we need from the casting and the detail within all the projects has resulted in a great collaboration.

Tom Winstanley, DirectorLondon Bronze Casting

3D printed casting model of a 2 meter large sculpture

Using 3D printing, we create a 2.2 meter high plastic investment casting model cast in bronze by the London Casting Company

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