The Megalodon Shark Jaw was commissioned by Point Defiance Zoo and Aquarium in Tacoma, WA.   For this project we started with a 24-inch great white shark jaw which was 3D scanned (the smaller white jaw in first photo).  It was then scaled up to size and carved with a CNC machine in foam.  We were then able to alter the foam carving to accommodate the cast teeth (supplied by Bone Clones).  The teeth are generally the only part of the skeleton that gets preserved since the rest of the skeleton, which is similar to modern sharks and is only cartilage, is rarely fossilized.  We then sculpted and textured the surface of the foam to simulate fossil texture.  A mold and cast were made so we could incorporate an internal armature which was bolted to the floor.  The aquarium wanted this to be a touchable, interactive exhibit and we didn't want the first human injured by a Megalodon shark to be from this cast!  After the cast was done we secured the teeth, all 138, and completed it with artist paints to bring out the details and to unify all the elements.