Making a Cardboard Head With a Secret Hiding Spot

We made a box in the shape of my son’s head.  We laser cut pieces of taskboard (corrugated cardboard works well, too) and laminated them together. The heads pivots on a dowel and is held in place by two magnets

We started by taking a series of photographs. We used software called 123D Catch to turn the photographs into a 3D model.

123D Catch made a polygonal mesh from the photos. Here's a screenshot of the mesh 

We then turned the polygonal model into NURBS surface so we could do some further modelling operations

We then modeled an elliptical cavity for the hding spot and put in holes that would be used for alignment, for the pivot and for the magnets.

We then used 123 Make to slice the model. It's important to measure the material accurately in telling the software how thick to make the slices; otherwise the final model will come out distorted

Then we laser cut all 212 parts and began assembling the pieces. We just added layer after layer and used yellow glue (white glue works just as well) to put them together.

A dowel pin is inserted and used so the head can pivot open.

Round magnets have been added on the top and bottom of the head so it snaps close and conceals the secret hiding spot