Acroterion
3D-Printed Mold and Plaster Cast
Client
Ephorate of Antiquities of Emathia
Location
Polycentric Museum of Aegae
Vergina, Greece
2021
The project encompasses a) the 3D scanning of an existing ancient acroterion, b) the production of modular, precision-engineered molds via 3D printing, and c) the casting and fabrication of mirrored plaster acroteria featuring intricate lion-head terminals. These architectural components are intended for placement on the left and right endpoints of the pediment on the Palace of Aigai’s restored facade.
a) The original acroterion was scanned using advanced photogrammetry techniques, capturing high-resolution detail to ensure historical accuracy. The resulting 3D digital model was refined and modified to align with the structural and aesthetic demands of the restoration design, serving as an extension of the sima and other decorative cornices that constitute the facade of the structure.
b) Leveraging the finalized 3D model, a modular mold was designed with a focus on both accuracy and ease of assembly. Given the complex geometry of the lion-head terminal, a hybrid production approach was employed, combining Fused Deposition Modeling (FDM) for initial mold segments with silicone casting for highly detailed areas, ensuring precise reproduction of fine details.
c) The final acroterion is cast using the assembled mold, requiring approximately 25 kilograms of plaster mixed with color pigments as specified by the conservation team. This tailored mixture follows a proprietary formula to achieve the desired aesthetic and material properties in line with the historical preservation guidelines.
a) The original acroterion was scanned using advanced photogrammetry techniques, capturing high-resolution detail to ensure historical accuracy. The resulting 3D digital model was refined and modified to align with the structural and aesthetic demands of the restoration design, serving as an extension of the sima and other decorative cornices that constitute the facade of the structure.
b) Leveraging the finalized 3D model, a modular mold was designed with a focus on both accuracy and ease of assembly. Given the complex geometry of the lion-head terminal, a hybrid production approach was employed, combining Fused Deposition Modeling (FDM) for initial mold segments with silicone casting for highly detailed areas, ensuring precise reproduction of fine details.
c) The final acroterion is cast using the assembled mold, requiring approximately 25 kilograms of plaster mixed with color pigments as specified by the conservation team. This tailored mixture follows a proprietary formula to achieve the desired aesthetic and material properties in line with the historical preservation guidelines.
Photogrammetry provides a precise digital representation of the original ancient element, which is then utilized throughout the design process to produce the final cast.
The production process includes creating a mold composed of both 3D-printed and silicone components, designed to ensure precise detailing and facilitate the safe release of the plaster cast.
The finished, painted cast is installed in its final position at the endpoint of the pediment.
