Terra cotta, original and scan. (click to enlarge view)

Wood angel, Vilnius Lithuania. (click to enlarge view)

Stone angel, original and reproduction. (click to enlarge view)

Honeoye Falls Millwork now offers on-site laser scanning of existing architectural elements. We can furnish instant, real time CNC files (3D images and databases), suitable for reproduction in any material. We use a portable, lightweight laser scanner (FastSCAN, manufactured by Polhemus of Burlington, VT) that produces minutely detailed three dimensional surface images when the handheld laser scanning wand is swept over an object, similar to spray painting. The image immediately appears on our computer screen. We can then furnish you with CNC files in whatever format is required for your CNC program.

At right, please note a terra cotta original and the minutley detailed 3D computer image. Flaws can be "edited" out in the software program, if necessary, before milling. Files can be precisely altered to allow for the shrinkage inherent in casting operations, such as terra cotta, or to furnish elements in other sizes. For instance, we had an inquiry to produce a 5 foot ice cream cone from a scan of the real thing. We have our own CNC milling capacity in wood, and can furnish scans to specialists in other materials.

This compact scanning system fits in a briefcase, and can be taken up on scaffolds or to other inaccessible areas. An example of the portability and utility of this system are shown at right in the photo of Jim Turner of HFM in the Church of the Dominicans in Vilnius, Lithuania. He is scanning the back side of a carved wood angel on top of the organ, a long ways from the floor on a somewhat shaky platform (You can see the transmitter in the back of the angel about at waist height.) The project was part of the reproduction of an historic 18th century pipe organ by a preservation group in the United States. Completed in 1776, this is the last remaining untouched pipe organ in Europe of this vintage. Our project was to help reproduce the "pipe shades", ornately carved baffles that go at the top and bottom of a set of pipes, restricting the airflow and modifying the sound of the organ. This historic organ has been declared a national treasure and no original parts are permitted to leave Lithuania. We scanned the historic elements in Lithuania, roughed them out on our own CNC milling machine here in the United States (see image at right), and then had local wood carvers apply a hand carved finish to the work.

The versatility of this system is virtually (pun intended) endless as CNC milling can be applied to any material that can be milled or cast: stone, terra cotta, concrete, wood, metal, etc. At right, you can see a cemetery angel carved in marble. The original was scanned by us and the files furnished to a stone carver, in the required format, from which were produced the beautiful reproduction seen alongside the original. As with the organ angels, these elements were roughed out by a programmed milling machine and then finished by hand.

Let us know about your challenging architectural reproduction project. We may be able to propose an innovative, money saving solution including laser scanning. Contact Jim Turner, Proprietor of Honeoye Falls Millwork, at 585.624.3340. Our email is hfmillwork@bluefrog.com, but call us for the fastest reply.