"These models were some existing handles
that some bondo was added to to simulate the material we wanted
to add. I want to emphasize that these were only a starting point
because one of the original goals to accomplish was to increase
the overall size of the handles by 10%.
Basically I used the MicroScribe to capture some of the 3D curves,
such as the parting line and outside contours. I also captured
many cross-sections to facilitate building the loft cuts. The most
critical feature to keep smooth and flowing was the parting line.
It was imperative for the mold making process. I modified those
curves (increased the size by 10 %) and used those curves to drive
the lofts and sweeps to create the part files. Of course, much
experimenting was done on tweaking the geometry to get the fillets
and rounding to fall into place. Several rounds of Z-Corp, SLS,
and SLA models were built from these files to verify the data."