Nomad
From the 1967 STAR TREK episode "The Changeling"
In 2017 I was asked by hyper-realistic painter ADAM ROTE to create a 1:1 sculpture of the Nomad probe to display at an art gallery show on science fiction pop culture that he was organizing.
The original prop was, no doubt, cobbled together from inexpensive and easily obtained objects available in the 1960s. However that was not the case in 2017! So I knew I would have to build almost every single piece from scratch.
Design and Planning
I initially found some very good fan blueprints online, but since I had to engineer the parts break-down and draw vector files for the laser cutter anyway, I ended up spending around 300 hours researching and drawing my own plans.
Engineering and Fabrication
I made the main components and details primarily from laser-cut 1/8" inch thick MDF. The body sections are stacked onto a length of PVC pipe for alignment, strength and to provide a channel for electronics wiring.
Construction 2
I engineered and cut an internal framework for structural integrity, support for the internal PVC, and as a backer for the side panels. I cut the conical pieces flat with a flexible pattern so they were pliable and formed like a giant paper model!
Construction 3
I glued these outer skins over inner supports and coated the insides with fiberglass resin for strength and rigidity. Then I coated the exteriors with Bondo filler. Once dry, I removed the internal supports and sanded everything smooth.
Construction 4
All of the cylindrical components are made from either PVC pipe or acrylic tubes. The Top (or "Shoulders") and Bottom Plates, Side Panels and Corners were all relatively simple since they were flat. Any that had detail were laser etched.
Fine Details
I vector-etched the locations of each of the "Shoulder" details to ensure proper placement. Those various details were all either laser cut or hand-made from styrene and solid chunks of Bondo filler cast from an ice cube tray.
Fine Details
I hand-sculpted the detail pieces for Nomad's head and base, then molded and cast them in resin. The top antenna was made from wooden dowels and sheet acrylic.
Finishing Touches
I painted Nomad flat grey with Design Master Platinum 232 for the shinier side panels and highlights to match the colors of the original prop. Basic LED lighting for the piece was provided at the 11th hour by local "Maker" Phil Bowers.
Final Thoughts
Overall, Nomad took me about 700 hours to research, engineer and construct. This piece was very challenging and difficult, as well as being a big learning experience. But both the client and I are very pleased with the results and, in the end, that's all that matters!