Fabrication
The whole adds up to more than the sum of its parts. I have worked for thirty years as a fabricator of countless objects. I owned a metal fabrication shop for ten years, specializing in high-end artwork, architecture, and industrial fabrication. I even had the honor of welding a sun shield for the Wide-field Infrared Survey Explorer, which is still floating in space. The work demanded the highest quality, with difficult finishes and tight deadlines. Each job was unique and required an inquisitive and exacting mind to complete.
I created objects for Philippe Starck, Barneys, Macy’s, Cooper Hewitt, Urs Fischer, the Smithsonian, Henson, and many others. I’m accomplished in all areas of fabrication, with a special enthusiasm for CNC fabrication techniques.
Running a job shop was the ultimate education—not only in the specifics of metalworking, but in how to meet the unknown with confidence and success. Every job presented new challenges that required research, initiative, and the ability to absorb and apply new information quickly. I routinely solved extremely complex problems while projects were in motion. I’m always striving to learn and have confidence that, given the time and resources, I can make almost anything.
I designed and fabricated an invisible sphere composed of 215 monitors and 215 cameras. The structure was modeled in Rhino and completed in just two months. The metal components were CNC plasma-cut, and I built custom jigs to accurately weld the sphere together. Each monitor was repurposed from a countertop television and reassembled into a custom metal sled, allowing for easy replacement and maintenance.
This is the most complex object I’ve ever designed and built. It features 27 computer-controlled axes of motion, all driven by a control system I personally designed and coded. The entire piece was modeled in SolidWorks and machined on a CNC machine that I built by hand. It has been exhibited internationally and is truly a marvel to witness. Here is a link to a page with more details.
This is one of the largest 3D printers in the world, with a build volume of 40 feet by 40 feet by 40 feet. It prints using salt and is driven by four computer-controlled motors. I designed it in SolidWorks and machined it myself in my shop.
The greatest challenge was controlling the flow of the salt. Depending on the ratio of salt to water, the material can behave like saltwater, a sludge with the consistency of ice cream, or a solid block—hard as a sugar cube. Maintaining the right consistency during extrusion and hardening was a complex task that required extensive experimentation and multiple design iterations. More details can be found on its page.
The printer was installed in a salt storage facility in Toronto and printed for 24 hours.
A scale model of the Slow Motion Car Crash. Designed in Solidworks and machined via Xometry. All the parts were shipped to my shop and only needed to be assembled.
Prototype city bike built with Karl Biewald
It was a fantastic day when over one hundred muppets showed up to my studio. I spent the next few months designing and fabricating over a hundred robotic puppet mechanisms built for the Jim Henson Company for Macy’s Xmas windows.
Robotic Sculpture built for Goldman Sachs
Sculpture built for Robert Lazzarinni
Robotic Sculpture built for the Jim Henson Company
Robotic Garfield Sculptures Modeled in clay molded and cast in resin for Macy’s Xmass windows.
Sled Prop for Spiderman the musical