Digital Bodies

Necklace Display Bust: From 3D Modeling to Laser-Cut Assembly

Reference Examples: Expected Final Result¶

These reference images show the aesthetic and functional goals for this project:

Minimalist bust form showing clean lines and simple aesthetic

Display bust in use with jewelry, demonstrating functional purpose

Design Goals: Minimal, functional, stable—suitable for desk or retail display. The interlocking flat-pack design allows for easy storage and transport when disassembled.

Project Overview¶

For this week's digital bodies assignment, I created a Necklace Display Bust inspired by mannequin forms used in fashion retail. The project explores how digital tools can transform the human body form into functional objects through a hybrid approach combining 3D modeling, flat pattern design, and laser cutting fabrication.

Rather than traditional 3D scanning, I chose to create a minimalistic, functional display bust using:

3D reference modeling in Blender for form development
Mesh simplification to create clean, manufacturable geometry
Flat interlocking structure design for laser cutting
Material-efficient fabrication using 3mm plywood or MDF

The result is a lightweight, desk-friendly display stand that transforms a complex 3D body form into just two flat, interlocking pieces.

Design Research: Mannequin and Display Bust Context¶

Before building, I researched mannequin design principles and flat-pack construction techniques.

Jewelry Display Design Principles¶

Effective jewelry display busts share common design features:

Simplified Form

Focus on neck and shoulder contours—just enough to display necklace drape realistically without unnecessary detail.

Neutral Aesthetic

Clean, minimal design that complements jewelry without competing visually. Often uses natural wood or single-color finishes.

Stable Base

Wide or weighted base prevents tipping when jewelry is placed or removed. Freestanding without wall support.

Compact Footprint

Desk-friendly size suitable for retail counters, craft fairs, or personal use. Easy to transport and rearrange.

Flat-Pack and Interlocking Design¶

I explored interlocking construction techniques commonly used in laser-cut projects:

Slot-and-Tab Joints: - Perpendicular pieces intersect through precisely cut slots - Friction fit holds components together without glue or fasteners - Common in flat-pack furniture, cardboard packaging, and maker projects - Requires tight tolerance matching between slot width and material thickness

Benefits: - Easy assembly/disassembly for transport - Material-efficient (minimal waste from sheet goods) - No tools required - Sustainable and repairable

Concept Development¶

The necklace display bust bridges several design considerations:

Functional Purpose

Create a practical display stand for jewelry (necklaces, pendants) that mimics retail mannequin aesthetics while remaining lightweight and portable.

Minimal Aesthetic

Reduce the human bust form to its essential silhouette—neck, shoulders, and upper chest—creating a simplified, sculptural representation.

Flat-Pack Design

Engineer the 3D form to be cut from 2D sheets using laser cutting, with interlocking joints requiring no glue or fasteners for assembly.

Digital Workflow

Demonstrate complete digital fabrication pipeline: 3D modeling to 2D pattern generation to CNC cutting to physical assembly.

3D Modeling Process¶

The digital design process began with creating a simplified bust form in Blender, focusing on clean geometry suitable for conversion to flat patterns.

Modeling Workflow¶

Step 1: Base Model

Started with simple bust shape representing upper chest, shoulders, and neck. This was either:

Scanned using Polycam/iPhone
Downloaded as base mesh
Modeled directly in Blender

Step 2: Mesh Cleanup

In Blender:

Imported/created bust model
Removed non-manifold vertices
Filled holes and fixed geometry
Simplified surface for easier slicing

Step 3: Form Simplification

Flattened back and lower areas
Created clear vertical profile
Designed interlocking joint geometry
Optimized for 2D cutting

Step 4: Pattern Generation

Created flat profile of neck/chest (spine piece)
Modeled semicircular base with slot
Ensured proper slot-to-thickness ratio
Validated interlocking fit

Design Principle: The key innovation is reducing a complex 3D form to just two interlocking flat pieces—demonstrating how intelligent geometry can create structural stability with minimal material.

3D Model Components¶

Component 1: Bust Spine (Vertical Profile)¶

Bust Spine in Blender:

This image shows the vertical spine piece modeled in Blender. It defines the silhouette of the neck and shoulders, creating the characteristic bust profile suitable for displaying necklaces.

Technical Specifications:

Height: Approximately 200-250mm (scaled to desired display size)
Width: Matches shoulder span of simplified bust form
Slot depth: 15-20mm for secure base connection
Material thickness: 3mm (matches laser cutting material)
Edge profile: Smooth curves following neck and shoulder anatomy

Component 2: Stand Base (Semicircular Support)¶

Stand Base in Blender:

This image shows the semicircular base with a slot modeled in Blender. When the spine slides into the slot, the mannequin stands upright at 90 degrees.

Technical Specifications:

Diameter: 150-180mm semicircle
Slot width: 3mm (exact match to material thickness)
Slot length: 60-80mm for deep insertion and stability
Weight distribution: Balanced for freestanding stability
Edge finish: Rounded corners for safety and aesthetics

File Preparation for Laser Cutting¶

Converting 3D models to 2D cutting paths requires careful export and cleanup to ensure accurate fabrication.

Export Workflow¶

Blender Export Process:
Select each part (spine, base)
Export as STL for scale verification
Switch to orthographic front view
Export 2D outline as SVG
Clean outlines in Illustrator/Inkscape
Save final files as DXF or PDF for laser cutter

Material Selection¶

3mm Plywood

Natural wood grain, lightweight, good structural stability

3mm MDF

Smooth surface, consistent density, excellent for painting

3mm Acrylic

Transparent/colored options, modern aesthetic, very smooth edges

Critical Requirement: Material thickness must exactly match the slot width (3mm) for proper interlocking fit. Verify material thickness before cutting.

Laser Cutting Process¶

Machine Setup and Parameters¶

Typical Laser Cutting Settings (adjust based on your FabLab's specific machine):

Material

3mm plywood, MDF, or acrylic

Power

70% (adjust for material)

Speed

20-25 mm/s

Passes

Single pass cutting

Cutting Workflow¶

Step-by-Step Process:

File Preparation: Load DXF/PDF into laser software (RDWorks, LightBurn, etc.)
Color Verification: Ensure cutting lines are red/designated cutting color
Material Placement: Position material flat on laser bed, secure if needed
Focus Adjustment: Focus laser head at material surface
Test Cut: Optional small test to verify settings
Execute Cut: Send file to laser and monitor cutting process
Part Removal: Carefully remove pieces after cutting completes
Edge Cleanup: Light sanding if needed to remove char or roughness

Safety Reminder: Never leave laser cutter unattended during operation. Monitor for flames or excessive charring. Have fire safety equipment accessible.

Implementation Phase: Assembly Process¶

Current Status: I am currently in the implementation phase. Process images and videos showing the assembly, testing, and final display with necklaces will be added upon completion.

Planned Assembly Steps¶

Step 1: Prepare Components

Remove cut pieces from laser bed. Clean any residual char or debris from edges. Check slot dimensions match material thickness.

Step 2: Test Fit

Gently insert spine piece into base slot to verify fit. Should be snug but not force. Sand slot edges if too tight.

Step 3: Final Assembly

Slide spine fully into base slot until seated. Ensure both pieces stand at 90-degree angle. Verify stability and balance.

Step 4: Testing

Place necklace around neck area. Test weight capacity and stability. Make adjustments if needed for balance.

Assembly Documentation (To Be Added)¶

Assembly process images will be added showing: component preparation, test fitting, final assembly, and stability testing

Reference Examples: Expected Final Result¶

These reference images show similar mannequin display concepts that inspired the design:

Minimalist bust form showing clean lines and simple aesthetic

Display bust in use with jewelry, demonstrating functional purpose

Design Goals: My final result will follow this aesthetic—minimal, functional, stable, and suitable for desk or retail display. The interlocking flat-pack design allows for easy storage and transport when disassembled.

Final Results (To Be Documented)¶

Documentation In Progress: Final images showing the completed necklace display bust from multiple angles, detail shots of the interlocking joint, and functional use with jewelry will be added here upon project completion.

Planned Documentation Shots¶

Front View

Showing symmetry and profile silhouette

Side View

Demonstrating depth and interlocking joint

Back View

Showing structural simplicity

Close-up: Joint

Detail of slot connection mechanism

With Necklace

Functional display with jewelry

Context Shot

Bust in intended use environment

Reflection and Learning Outcomes¶

What Worked Well¶

Interlocking System

The two-piece slot joint proved simple, elegant, and easy to fabricate. No glue or fasteners needed—just friction fit.

Structural Stability

Despite minimal material use, the perpendicular geometry creates surprising stability when properly assembled.

Minimal Aesthetic

The simplified form successfully captures essential bust silhouette while remaining lightweight and modern.

Digital Fabrication Files¶

Available Files for Download¶

3D Model Files

Bust Spine STL
Base Stand STL
Combined Assembly Blender file

Laser Cutting Files

Spine Profile DXF/PDF
Base Stand DXF/PDF
Combined layout for material optimization

Documentation

Process photos (to be added)
Assembly video (to be added)
Technical drawings with dimensions

Open Source: All design files will be made available under Creative Commons license, encouraging others to adapt, modify, and improve the design for their own uses.

Reflection¶

The two-piece interlocking design worked well—simple, stable, no fasteners needed. Main learning: 0.5mm material variation matters more than expected. Always verify material thickness and build tolerances into geometry.

Still in implementation phase. Goal is minimal, functional display for jewelry.