First, the cardboard, courtesy of Glen at the local Smurfit Kappa cardboard factory. He gave us a pile of reject cardboard sheet (made from recycled paper).
We hoped to carve out a shape from a block of cardboard but a test showed that it didn't leave a nice finish. So, we modified the design to use only squares, and got the rulers, set squares and Stanley knives out.
We glued the 200-odd pieces using starch to ensure the card could still be recycled; sprayed it with fire retardent, and ta-da!.
Credit for the initial idea goes to the designer David Stark whose awesome laser-cut giant cactus inspired us to do something similar.
