Method of three-dimensional theming

Abstract

A method of fabricating a thematic design article is disclosed. One of the embodiments of the method comprises the step of formulating from a three-dimensional computer model of an article, design parameters for panel elements of the article. The method further comprises the step of controlling a wire bending device responsive to the design parameters to form the panel elements, wherein the panel elements are comprised of horizontal and vertical sub-elements comprising continuous sub-panels, linear cut to form sub-panels, or a combination thereof.

1 . A method of fabricating a thematic design article, comprising the steps of:
 formulating from a three-dimensional computer model of the article, design parameters for panel elements of the article; and,   controlling a wire bending device responsive to the design parameters to form the panel elements, wherein the panel elements are comprised of horizontal and vertical sub-elements selected from the group consisting of continuous sub-panels, linear cut to form sub-panels, and a combination thereof.   
   
   
       2 . The method of  claim 1 , further comprising the step of assembling a plurality of the panel elements into a first panel section. 
   
   
       3 . The method of  claim 2 , further comprising the step of connecting the first panel section to a second panel section. 
   
   
       4 . The method of  claim 1 , further comprising the step of assembling a plurality of the panel elements into a first panel section of horizontally bent wire. 
   
   
       5 . The method of  claim 1 , further comprising the step of assembling a plurality of the panel elements into a second panel section of vertically bent wire. 
   
   
       6 . The method of  claim 2 , further comprising the step of applying a matrix material to the first panel section. 
   
   
       7 . The method of  claim 1  wherein the formulating step includes the sub-step of identifying a gauge for a wire. 
   
   
       8 . The method of  claim 1  wherein the formulating step includes the sub-step of identifying a material composition for a wire. 
   
   
       9 . The method of  claim 1  wherein the formulating step includes the sub-step of determining a volume of the article. 
   
   
       10 . The method of  claim 1  wherein the controlling step includes the following sub-steps:
 bending a first continuous wire to form a horizontal panel sub-element;   bending a second continuous wire to form a vertical panel sub-element; and,   joining the horizontal and vertical panel sub-elements to form the panel element.   
   
   
       11 . The method of  claim 1  wherein the controlling step includes the following sub-steps:
 bending linear, cut to form wire to form a horizontal panel sub-element;   bending linear, cut to form wire to form a vertical panel sub-element; and,   joining the horizontal and vertical panel sub-elements to form the panel element.   
   
   
       12 . A method of fabricating a thematic design article comprising the steps of:
 formulating from a computer model parameters of a three-dimensional article, wherein the parameters comprise horizontal, vertical, and otherwise intersecting elements of a surface;   creating an instruction set from the parameters and intersecting elements of a three-dimensional representation of the three-dimensional article, whereby a computer numerical controlled wire bending apparatus forms the intersecting elements;   integrating the intersecting elements to form a panel section;   assembling a multitude of similarly fabricated panel sections to form an accurate shape of the three dimensional article; and,   processing the panel sections and applying a matrix material to the assembled panel sections.   
   
   
       13 . The method of  claim 12  wherein the computer model is a CAD (computer-aided design) model. 
   
   
       14 . The method of  claim 12  wherein the intersecting elements are wires. 
   
   
       15 . The method of  claim 12  wherein the matrix material is a polymeric material selected from the group consisting of polyvinylchloride and polyethylene. 
   
   
       16 . The method of  claim 12  wherein the intersecting elements are formed by the wire bending process in a continuous manner. 
   
   
       17 . The method of  claim 12  wherein the intersecting elements are formed by the wire bending process in a non-continuous manner. 
   
   
       18 . The method of  claim 12  further comprising the step of applying paint and design elements to the assembled panel sections. 
   
   
       19 . A thematic design article formed from the method of  claim 1 . 
   
   
       20 . The thematic design article of  claim 19  comprising a boat, tree, root, building, cave, mountain, rock, waterfall, pool, pond, river, stream, character, free form sculpture, or nature scenery.