Lexus made an exact driveable replica of its model IS using 1,700 sheets of cardboard.
The car was built entirely by hand using laser cutting technology and water-based glue. Lexus gave London-based companies LaserCut Works and Scales and Models a digital 3D model of the car to plan the construction of its principal parts: the dashboard, the seats, the main body and the wheels.
LaserCut Works then cut the sheets of cardboard into 10 millimetre slices. Each slice was given a reference number to ensure everything was assembled in the correct order. The water-based wood glue used to hold the car together had to be given 10 minutes to dry after each application.
The car is set on a steel and aluminium frame and is equipped with an electric motor, allowing it to drive backwards and forward. A team of five people assembled the car.
The cardboard car will be revealed to the public at the Grand Designs Live show in Birmingham, London on October 8.
Here’s how Lexus and LaserCut Works assembled the car:
LaserCut works used the Computer-Aided Design (CAD) of the Lexus Model IS to divide the car into principal parts. The team then began planning how to produce a carbon copy in cardboard.
After dividing the car up, the five-person team began the laser cutting process to make exact replicas of its principal parts. The laser cutting process took a matter of weeks.
The car was then delicately assembled by hand using glue. There was no room for error, as changes couldn't be made once the glue dried.
Once the body of the car was completely glued together, the cardboard car was set on a steel and aluminium frame.
The completed car boasts an impressive fully fitted interior, functioning doors, headlights, and rolling wheels. It took three months to create the cardboard car.
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