Traditional Processes and 3D Printing
For years the typical means of creating bigger pieces was to first create foam enlargements using a variety of manual methods. This is how I made the 5′ Doxie Bump. Some of companies spray a layer of clay over the foam enlargement for the artist to bring back detail, add texture, and make any needed modifications. That is still a very popular way of creating enlargements.
However, in recent years sculptors have started to embrace the 3D print industry for their enlargements. We now have the option to have an existing sculpture 3D scanned. The file created by the scan can be used to print the piece to any size using a variety of print media.
For example, as the images here show, there is now a material that can be printed and directly cast at the foundry, taking the place of the wax in the traditional lost-wax process. Because the process of removing the material completely from inside the shell is more complex, only a limited number of US foundries currently offer this service.
This process gives me a great deal of flexibility to enlarge pieces to meet the needs of the buyer. I have used this process for multiple enlargements, the largest of which is a 7′ high Wall Street Waltz being installed in San Salvador. Interestingly, it was the height limitations of the transport that determined the size of the statue. Oh, how I would have loved to make it larger!