Accurately recreating an undulating landscape from a 3D mesh model.

[Jaques]

Hello.
I have the challenge of accurately reproducing a dune landscape in 1:25 from a digital 3D mesh.
I first made a rough physical model using a fine aluminium mesh and then by plotting over a hundred heights, managed to recreate this undulating landscape using Rhino and Zbrush as a 3D mesh. This mesh will be adjusted in 3D over the next month and I will then have the task of translating it back into a physical model.
Ideally I would like the physical model to be a thin 'skin' layer rather than cut polystyrene or similar.
Does anyone have a good method for tackling something like this?
It could obviously be done using 3D printing but it would end up being a patchwork of pieces as the footprint of the model is about 60cm square.
Many thanks!

[scottie3158]

Hello.
I have the challenge of accurately reproducing a dune landscape in 1:25 from a digital 3D mesh.
I first made a rough physical model using a fine aluminium mesh and then by plotting over a hundred heights, managed to recreate this undulating landscape using Rhino and Zbrush as a 3D mesh. This mesh will be adjusted in 3D over the next month and I will then have the task of translating it back into a physical model.
Ideally I would like the physical model to be a thin 'skin' layer rather than cut polystyrene or similar.
Does anyone have a good method for tackling something like this?
It could obviously be done using 3D printing but it would end up being a patchwork of pieces as the footprint of the model is about 60cm square.
Many thanks!

Sorry but I don't have the first idea about printing.

[Steven000]

I'm not sure if I understand your question, but if you need a physical model of a 3d model imho 3d printing is the way to go, most (FDM) printers today can print 20x20cm, so that would result in 9 square pieces for your 60x60cm model.

You can also 'cut/slice' the 3d model in cross sections, then render/print these out, recreate those sections on cardboard/hardboard/balsa... glue them on a 60x60 square piece of mdf...
Then fill those sections with plaster/foam...
For a 'thin skin' you could use that plaster model as a mould for a glass-fiber skin...
Or build a large vacuum-box and heat a large plastic sheet over the plaster model and pull it vacuum...

I would 3d print it.