After the digital sculpt was complete, I cut it into parts to fit my printers. Done in zbrush. The head was split into 12 main parts, which were bolted together. Gaps between parts filled. The cuts were made to follow the outline of the scales to reduce visibility of the seams.
ALT Part of the rex head, printing complete and awaiting support removal
ALT After bolting together two parts and filling/cleaning up the seam
ALT Parts of the mandible being bolted together
ALT The full assembly after bolting and seaming, from behind
Proud to present my lifesize T. rex head, affectionately named Hannibal. I created this myself from start to finish- digital sculpture, 3D printing, painting, etc. Quite a learning curve involved but very pleased with how he turned out.