I have been asked to help with the manufacturing of a bust(s) these would be full size to 1/10 scale. I am not sure what is the best method of obtaining the design (3d scanner?) would be I also need some direction for what is the best way to make it. CNC Mill is what I am thinking. I am think the best material would be clear or translucent acrylic but may also want to consider wood as an option. I don’t think I want to print it but that might be an option. These would mostly be one offs not multiples of the same design so I believe that casting would be too much work and then there is the weight consideration.
I doubt this is an option with the equipment we have available. Busts contain undercuts and are not really suitable for three axis milling. If it were me, I would take the 3d model and make a inverted mold. 3D print that and use acrylic resin to cast the bust.
I wouldn’t suggest printing a mold directly. As a general rule, if you’re casting a solid material you would want to make the mold flexible. One might get away with printing the mold in NinjaFlex, but you’d need to be sure to coat the inside VERY THOROUGHLY with mold release or petroleum jelly, else the resin would likely bond straight to the ABS.
Bright side, if you’re only doing a one-off casting, you wouldn’t have to worry about making a multi-part mold as you could just rip it open and throw it away.
Fortunately, making molds and casts isn’t actually very much work at all, it just takes time to let things cure. Honestly it would be considerably less work than learning to use any of the CNC machines to an extent you’d get good results on a complicated form like a bust, and as was mentioned, I don’t think any of our tools can really do undercuts. Casting is likely the only way you’ll get a really good bust.