Prof. Resch has been using computers to observe, analyze, design and manufacture structures for some time. Although he has exhibited widely, this is the first use of his modular system to become a permanent structure. Each piece of aluminum sheeting used for the Egg was made on a plotter, run by computer.

Resch modified a Gerber plotter with a custom-made tool that could score, or cut, the aluminum. Each piece was scored where it would later bend and/or connect to another; and was then cut out as a unit, and precise holes drilled. Preplanning and programming to cut and score the pieces on the plotter took as long as the scoring and cutting itself, some two months time each.

Robert McDermott produced all the control tapes to run the plotter. Jim Blinn, who also had provided assistance with mathematics and programming, designed a program to see, on a computer display, the various patterns of coloring on the Egg. The plotter engraved each piece, or facet, with an identifying number which corresponded to an assembly map for locating it precisely on the Egg. The pieces were then masked for proper color anodizing, which was done in Ogden, Utah, and air freighted to the Vegreville site for assembly.

The pieces were designed to fit with an interlocking system of bolt connections so that tabs extending from the star-shape planes would be concealed behind triangular pieces of appropriate color, forming the visible pattern. Specific interior triangular pieces (backing plates) have tabs which bend away from the plane and receive the bolts, connecting them to the steel strut supports. Much like umbrella spokes, the struts carry the wind load from the skin to the main internal axis. The pieces were shipped in eight crates to be put together like a giant jigsaw puzzle. Amazingly, it went together without a hitch.