As before, we cut the parts out on the CNC router from our original design.
The parts were glued together and sanded.
After assembly was lasering to mark and etch the notch, which we carved and chiseled to make it deeper than our previous one.
The first layer of paint was primer grey, followed by black and silver. Once the body of the chip had a beautiful matte black finish, it went back into the laser for the manufacturer’s mark before a final protective coat of paint.
It posed for a few pictures before heading off to meet Sparky, and we’ve posted them on flickr.
The original Sparky design side-by-side with the plush puppet and its new chip.