Artist Mark Kessler was commissioned to produce a Styrofoam replica of the Star Wars Robot BB8 for a private collector. He started with a 20” – .9 lb density expanded polystyrene (EPS) sphere from Universal Foam Products that he covered with a paper mache glue. He then used Bondo Glass, a versatile repair putty, which he sanded to a smooth finish. After he painted it, he used a shiny laquer to give it the “metallic” appearance. Impressive!
