Client context
European film production
Film set functional tech shells — hero props with engineering margins
On-camera objects requiring believable industrial detail, internal space for practical electronics, and rapid iteration under production pressure.
- Film
- Engineering
- Finishing
Hero units
3 + spares
Tightest tolerance feature
±0.15 mm (insert fit)
Primary process
FDM + inserts + paint
Problem
Art department needed hero-closeup quality while accommodating last-minute practical changes. Parts had to mate with machined inserts without looking 'printed'.
Constraints
Confidentiality, overnight iteration windows, and strict on-set safety margins for edges and heat.
Solution
Hybrid fabrication: printed shells with bonded metal inserts, controlled texture break-up, and a finishing stack tuned for camera-friendly contrast.
Production process
Locked CAD revisions → print windows matched to unit schedule → insert bonding with fixture cure times → wet sanding ladder → on-set spare kit.
Final result
Delivered three hero variants plus spares. Zero on-set failures across principal photography for the featured unit.