Bobbleheads, you remember them, small figures with a spring-mounted comically large head. They brought joy to millions of car drivers every day as at least 97.5% of all registered cars in the 1960’s had bobbleheads mounted to the dash. Years later bobblehead popularity has waned but [Luis] is trying to bring them back, this time not as your iconic sports hero but as YOU!
[Luis] uses software called Skanect along with his Kinect to scan a persons geometry. There is a free version of Skanect but it is limited to exporting STL files no larger than 5,000 faces. That means that scans of large objects (including people) come out looking noticeably faceted. [Luis] came up with a work-around that results in a much finer detailed scan. Instead of scanning an entire person with one scan, he would do 4 separate scans. Since each individual scan can support 5,000 faces, the resulting merged model can be up to 20,000 faces. Check out the comparison, the difference between the two scanning methods is quite noticeable. MeshMixer is the software used to merge the STL files of the 4 separate scans.
Once the full body is assembled in MeshMixer, it is time to separate the head from the body. A cylindrical hole is then made in the bottom of the head and the top of the body. This hole is just slightly larger than the spring used to support the head. The parts are then printed, painted and assembled. We have to say that the end result looks pretty darn good.