We would love to be able to produce the carved wood and plaster elements of the riad ourselves, if possible and financially feasible. Making the ornate wood ceilings, decorated doors, and plaster designs ourselves would be incredible.

I had a major breakthrough today that culminates several weeks of research with friends in the arts and engineering fields. Cost estimation, figuring out how to price carved wood, brass, and plaster (molds or the panels themselves) has been difficult. I initially began to look at laser etchers, but found them expensive in both up-front costs and usage costs. I spoke with Herb Robb, artist of multiple medias, and he recommended considering routers, while an engineering friend of mine recommend water-etching or perhaps building a smaller version of a CNC Router.

From this point I began to research 3D printer to making molds for plaster and concrete, and maybe even producing acrylic lattice work (as opposed to wood). I am not a fan of resin or plastics, so I backed away from the lattice idea and focused more on mold making. While researching 3D printers, I came across Inventables and found a 1m x 1m wide automated router called the X-Carve. This system appears to be a small business or home user version of industrial CNC Routers, but with a price tag of $2,000 as opposed to $7,000.

This system, or a similar one, could be the solution I have been seeking to make my own carved wood panels, intricate wood lattice work, and carved brass inlays for doors.

The 3D printer seems to be the most viable solution to make the plaster and ceramic molds I need to create intricate 3D plaster reliefs, and to create custom ceramics to decorate the house.

Now, this course of action gives me a fixed cost of around $12,500 for the printer, router, and other support items (work bench, tools, kiln, sander etc), leaving my variable cost to be material, electricity, and maintenance. My running estimate for plaster molding is clocking in around 2,000 square feet at $5 per square foot. I do not have a good carved wood estimate at this time, but I am estimating it will be similar to the plaster – so 2,000 square feet at $10 per square foot will work for now. I have done some limited research on brass, and found that it clocks in at $50 per square foot at 1.62mm thickness. I am guessing 50 square feet of brass to account for multiple door panels.

Bottom Line: I can make all of my carved wood, intricate plaster work, brass engraved panels, and custom ceramic for $50k. 

Here’s the breakdown:

Item	Cost
3D Printer	4,000
Automated Router	4,000
Home Kiln	2,500
Shop Accessories	2,000
Plaster (Materials for 2,000 Square Feet)	10,000
Wood (Materials for 2,000 Square Feet)	20,000
Ceramic Materials	1,000
Brass Materials	2,500
Gross Cost	46,000
Estimated Maintenance at 10% of Gross	4,600
Net Cost	50,600

Other considerations include ‘throughput’ and relief.

• How long will it take to make the items to ensure they are ready for installation on time, and that they match the actual final dimensions of the house?

This question implies we must identify the dimensions early on with the architect and builder, and ensure we have contractual remedies if they do not adhere to the specs. We also must ensure the tile and the plaster are seated flush to one another to avoid odd changes in relief. This means clear communication with the subcontractors and builder prior to install.

Do you have any advice or experience with this? Please tell us what you think in the comments.

-Mike