Laser Cut Cardboard Model of a T-Rex Head

This fun 3D model project is a great way to show off how you can create 3D stacked layered models utilizing your Epilog Laser system and 123D Make from AutoDesk.

Update: We originally used 123D Make for this project, but it is no longer available. Fortunately, you can achieve the same results with Slicer, available as a standalone app or an add-in for Fusion 360.

Autodesk, Inc. provided the 3D model used to create this T-Rex sample - download the 3D model.

Create your own 3D model T-Rex head out of inexpensive corrugated cardboard by cutting out individual layers and dowels, then gluing and stacking the numbered layers to create your very own T-Rex head. It will be roarsome!

Download Now

3D T-Rex Head Model - Laser Cut and Layered Cardboard.

Cut the T-Rex cross sections utilizing the Color Mapping feature.

Cut the dowels out of the 1/4" wood.

Assemble the T-Rex Head using the dowels and super glue.

Materials Needed

Corrugated cardboard sheets - we used 30" x 20" sheets and got ours from Uline.
1/4" MDF Wood Sheet - we recommend at least a 14" x 2" sheet for at least one set of dowels.
Glue - we recommend something fast drying like Insta-Cure.
An Epilog Laser System.

We used a 60-watt Fusion 32 with Color Mapping turned on.

Color Mapping Settings:
Blue & Green lines set to speed 15%, power 100% and frequency 100.
Red lines set to speed 100%, power 20% and frequency 100.

Start by opening the design file. You'll notice that the slices are grouped into four sheets and laid out in order of the number on each slice. The numbers correspond to the order that you place the slices on the square dowels when building the 3D model. We chose to reorganize the slices after exporting them from 123D Make to make the assembly process quicker.

If you are using a smaller system than the Fusion 32 you'll need to rearrange the slices of the T-Rex to fit the sheet size you are using. We recommend keeping the slices in order so you can build the model as the slices are coming out of the laser.

Place your first sheet of cardboard in the laser and, utilizing the Color Mapping feature and the suggested speed and power settings above, cut your first sheet.

Once you have cut your first sheet of slices you can begin assembling your 3D T-Rex Head Model. Begin with slice #1.

Start with the longest dowel, dowel #1. Place the longest dowel in the hole in the number 1 slice then add slices 2 and 3. Then add the #2 middle length dowel to the second hole, which starts in the number 3 slice. From there keep gluing and sliding on slices until you are finished.