2. Digital bodies

Research & Ideation

This week, my research explored how to digitally develop and modify anatomical models, with a specific focus on fetal woman body structures. The goal was to understand how to generate accurate representations of the female body during pregnancy, especially in the fetal stage, and prepare these models for digital fabrication workflows. I studied the anatomical changes that occur in pregnant and fetal-stage female bodies, including torso curvature, abdomen expansion, pelvic shifts, and overall proportional adjustments. This research supports applications in digital fashion.

Picture I draw using canva that represent the pregnant woman body structure

My ideation centered on how to transform fetal woman body forms into clean, editable digital assets that can be refined, segmented, and prepared for slicing and laser cutting.

References & Inspiration

My work drew inspiration from the lectures of Anastasia Pistofidou, on digital bodies and continuous tutorial support. Additional references included online MakeHuman community models showcasing diverse body shapes and detailed anatomical features, digital tailoring and product development workflows used in 3D clothing software and tutorials from Blender, Fusion 360, and digital slicing communities demonstrating how to convert 3D bodies into layered 2D forms. Real-world applications in fashion and body-centric fabrication, as these fields employ similar workflows to produce physical replicas or design prototypes.

• MakeHuman community models that show diverse body shapes and detailed anatomical features.
• Tutorials from Blender, Fusion 360, and digital slicing communities that demonstrate how to convert 3D bodies into layered 2D forms.
• Pistofidou, A. (2025), Digital Bodies Lectures and Tutorials.
  These references helped shape my approach to generating accurate, editable digital body assets.

Tools

Throughout the week, I used several digital tools at different stages:
- MakeHuman
- For creating and customizing different human bodies. - Used sliders to adjust gender, age, muscle, weight, height, body proportions, etc. - Blender
- Used for importing the MakeHuman models. - Cleaned up geometry and removed unnecessary or non-essential body parts. - Adjusted mesh topology so it becomes easier to slice later. - Exported refined body files in formats compatible with Fusion 360. - Fusion 360 (Slicer)
- Imported edited 3D bodies for slicing. - Generated layered slices suitable for laser cutting. - Prepared layout and thickness settings for material selection.

Process and workflow

Step 1: Developing Digital Bodies in MakeHuman

I created multiple human bodies with different proportions to test how varied body structures respond to slicing and fabrication. Adjustments included torso length, arm thickness, and body mass distribution to create realistic variations.

Step 2: Exporting Models to Blender

Each MakeHuman model was exported as an .obj or .stl files.
In Blender, I:
- Removed unnecessary geometry such as hands, feet, or internal mesh layers by using following procedures
- I add a cutting object (cube) over the part to remove.
- Select my main mesh imported from makehuman community.
- Then click Modifiers - Boolean - set Operation to Difference - choose the cutting object.
- Finally I click apply the modifier and delete the cutter.
- Smoothed out surface irregularities for cleaner slicing.
- Here I select my mesh in Object Mode.
- Then Right-click - select Shade Smooth to smooth the surface.
- Checked the model from multiple angles to ensure symmetry and balance. - Ensured proper orientation and scaling before export.

Step 3: Sending Clean Mesh to Fusion 360

I imported the refined Blender file into Fusion 360’s slicer environment.
I tested:
- Different slice thicknesses. - Various stacking directions (vertical, cross, or radial slicing). - Material layout to match potential laser-cut sheet sizes so I used the following procedures,
- The model file importing was done from Blender as an .STL file
- The model was checked to ensure it was properly scaled for my case the uniform scale was selected and make the height 500 cm.

    - In the Construction Technique panel, the interlocked  slices Structure option was selected. This method creates interlocking slices along the X and Y axes to form the 3D structure.  
    - In etting Manufacturing Parameters  
      - Material Size: 1000 cm × 600 cm  
      - Material Thickness: 0.4 cm     
      - Slice Direction: Adjusted to 90 degree orientation to achieve balanced interlocking slices and structural stability.    
      - Slice Count: I make 3 sheets and 63 parts but It can be increased or decreased to refine the level of detail and ensure proper fit within the material sheets.  
    - Adjusting Slice Distribution  
      - I make 34 for 1st axis and 15 for 2nd axis until the spacing and alignment of the slices were fine-tuned to ensure even distribution and avoid overlapping or missing intersections, especially around complex areas like the head and arms.  
    - Adding Assembly Slots  
      - The software automatically generated interlocking slots where the X and Y slices intersect. Slot depth and width were adjusted to match the 3 mm material thickness for a snug fit.  
     - Arranging Parts on Sheets  
      - The generated slices were automatically laid out on virtual sheets (1000 cm × 600 cm). The layout was reviewed to ensure all parts fit within the available boards.  
    - Exporting for Laser Cutting  
      - Once the layout was finalized, the design was exported as 2D vector files (.DXF). These files contain the outlines of each slice, ready to be sent to the laser cutter.

Step 4: Preparing for Laser Cutting

After generating slices, I arranged them for fabrication:
- Flattened each layer into a 2D pattern. - Exported files in DXF format. - Checked alignment numbers and assembly sequence.

tep 5: Review and Iteration

I repeated the process for several body variations to evaluate which structures slice best, and which body shapes require additional mesh correction.

3D Modeling

At first, I attempted to create my own 3D model using the Polycam app on my Android phone. The scanning process worked successfully, and I was able to generate a 3D output of the TP Link. However, the app required a paid upgrade to export the model in .STL format, which made it impossible to download and use the file for further processing.

To work efficiently within the limited time available, I decided to use an open-source sewing machine model from Thingiverse. The model was already close to what I needed, with proportions and structural details similar to my intended design. I imported the .STL file into Blender for editing and preparation.

In Blender, I cleaned and simplified the mesh to make it suitable for fabrication. I removed unnecessary details and corrected a few disconnected surfaces to ensure the model was watertight and ready for slicing. The goal was not to redesign the sewing machine but to optimize it for laser cutting.

I checked the overall dimensions to make sure the model would fit within the laser cutter’s working area. Once the model was finalized, I exported it as an .STL file for slicing.

Slicer
I used Slicer to convert the 3D model into 2D layers suitable for laser cutting. Given the compact and detailed structure of the sewing machine, I selected the stacked slices technique to maintain accuracy and stability. Slicer generated the cutting layout, which I later refined in LightBurn to ensure proper alignment and material efficiency.

Assembling
The assembly process was straightforward. Following the sequence provided by Slicer.

Final Outcomes

By the end of the week, I achieved the following results:
- Successfully developed multiple human bodies using MakeHuman, each representing different proportions and characteristics. - Cleaned and optimized several body meshes in Blender, ensuring they are suitable for slicing and physical prototyping. - Imported these bodies into Fusion 360 and generated laser-ready slices. - Produced 2D files that can be used for laser cutting, enabling the construction of layered physical body forms. - Improved the entire pipeline efficiency from digital body creation → Blender cleanup → Fusion 360 slicing.
This workflow is now repeatable for future prototypes, allowing me to quickly generate body forms for wearable technology, soft robotics, garment prototyping, or experimentation with organic shapes.

Production Files

File: Digital Body STL 3D Model (.STL):
File: Digital Body Laser Cut DXF 3D Model (.STL):
File: Digital Body STL 3D Model (.STL):
File: Digital Body Laser Cut DXF 3D Model (.STL):