The cardboard car was built for Lexus by London-based specialist companies LaserCut WORKS and Scales and Models. Lexus provided a three-dimensional digital model of their IS sedan, which company technicians then divided into working sections. Each section was then digitally rendered in slices just 10mm thick, resulting in a series of two-dimensional profiles which were precisely laser-cut from cardboard sheeting.
Organizing the many similar yet distinctly different cardboard sheets was a project in itself; each layer was given a unique reference number to ensure there were no errors when it came to final assembly. At this point, the computers yielded control to their human masters – actual people worked hands-on using water-based wood glue to attach each cardboard sheet to its neighbor. Since every application of the glue required 10 minutes to set, the entire assembly process took three months to reach the finish line!
Though LaserCut WORKS and Scales and Models can boast extensive experience in the design and creation of prototypes, architectural models and bespoke commissions, constructing a life-size drivable Lexus IS sedan from cardboard required them to push the envelope in a number of new directions. Luckily for all concerned, not a single paper cut was suffered by any of the participating staff. (via ©WENN.com)


