PROJECT NAME (for ease of discussion): WCHS Skull
CLIENT: West Carrollton Schools
VENUE (Name, City/State): West Carrollton High School (exterior)
West Carrollton, OH
YEAR: 2025
Creating a Custom Campus Landmark
Scenic Solutions partnered with West Carrollton Schools to fabricate a custom oversized skull sculpture for the exterior of the newly constructed West Carrollton High School. Designed as a gathering place where students could take photos and celebrate school spirit, the sculpture serves as a permanent campus landmark inspired by the school’s Pirates mascot.
Turning a Concept into a Large-Scale Sculpture
From Client Sketch to Digital Prototype
The project began with a simplified client drawing outlining the desired appearance of the sculpture. Scenic Solutions transformed that concept into a fully engineered fabrication plan through research, development, and digital modeling.
- Produced a 1:48 scale prototype using a 3-D printer for client review and approval.
- Created a larger 1:8 scale prototype to determine how the sculpture would be divided, supported, and assembled.
- Used the approved prototype to guide fabrication of the full-scale sculpture.
Engineering for Fabrication and Assembly
The sculpture required careful planning to accommodate fabrication size limitations while maintaining the appearance of a single continuous structure.
- Divided the sculpture into 23 individual sections.
- Engineered assembly locations to preserve the finished texture of the sculpture.
- Designed aluminum framing to provide structural integrity and secure attachment between sections.
Robotic Milling and Scenic Finishing
Precision Fabrication
Once the digital model was finalized, Scenic Solutions used its KUKA robotic milling machine to carve each section of the sculpture.
- Transferred the approved digital model directly to the robotic milling system.
- Used robotic milling to achieve precise, repeatable fabrication of each section.
- Combined digital fabrication with custom metal framing to prepare the sculpture for final assembly.
Durable Outdoor Construction
The completed sections were finished using materials selected for long-term outdoor performance.
- Applied a durable spray-on hard coating at a local automotive coatings facility to create a protective outer surface.
- Painted the sculpture using exterior house paints selected for weather resistance.
- Delivered and assembled the completed sculpture on site at West Carrollton High School.
A Lasting Symbol of School Pride
The finished skull sculpture provides West Carrollton High School with a distinctive outdoor landmark where students can gather, celebrate school spirit, and create lasting memories. By combining digital modeling, robotic milling, structural fabrication, protective coatings, scenic painting, and on-site installation, Scenic Solutions transformed a simple concept into a durable feature designed for years of outdoor use.
Scenic Solutions: Custom Sculptural Fabrication Specialists
Scenic Solutions designs and fabricates custom sculptures, themed displays, and large-scale architectural features for schools, attractions, museums, and public spaces. This project demonstrates our ability to guide a concept from initial sketch through digital prototyping, robotic fabrication, structural engineering, scenic finishing, and final installation to create durable landmarks tailored to each client’s vision.