Guinness Toucan
This project started as a 3D model based on a 2D illustration. It was printed out in pieces, glued together, and bodyworked smooth. A 4-part rubber mold was made, housed by a 6-part fiberglass mother mold. The wings were molded separately so that they could be cast solid. The main body was then rotocast with the solid wings in position. After de-molding, it was filled with expanding foam for rigidity. To achieve the fake Guinness, an acrylic pint glass was painted and filled with expanding foam tinted off-white. It can be removed from the bird by unscrewing from a threaded insert in the beak.