Performer Safety Standards
All wearable components tested for skin safety, weight distribution, and performer comfort during extended filming periods.
Film & Entertainment SolutionsView All Industries
Bringing Fiction to Lifewith Industrial 3D Printing
Forge Labs manufactures film props, costume components, creature parts, and set hardware for productions working against hard delivery dates. Our film and TV 3D printing workflows support hero props, replicas, wearable parts, and paint-ready builds that hold up on camera and on set.
Production Lead Time
1-3 days
Detail Resolution
0.1mm
Projects Delivered
500+
Material Options
20+
Film & Entertainment Overview
Trusted by Leading Film Studios
Forge Labs has supported film and television productions across North America with printed parts that have to look right, fit performers correctly, and arrive on schedule. From intricate hero props and costume details to repeatable set components, our additive manufacturing workflow compresses fabrication time while preserving the surface quality and durability needed for production use.
Where additive creates leverage
Built for faster film & entertainment decisions
Forge Labs helps teams move from design validation to production-ready parts without waiting on tooling lead times. Consolidated assemblies, lighter parts, and faster revisions give engineering teams more control over schedule, cost, and performance.
Key manufacturing benefits
- Accelerate development timelines and compress design cycles, enabling faster innovation and reduced time-to-market.
- Eliminate expensive tooling requirements, reducing upfront investments and enabling economical low-volume production.
- Lightweight builds ideal for wearable props through advanced additive manufacturing solutions tailored for film & entertainment applications.
- Durability for stunt work and heavy handling through advanced additive manufacturing solutions tailored for film & entertainment applications.
- Eliminate expensive tooling requirements, reducing upfront investments and enabling economical low-volume production.
- High-detail resolution for paint-ready surfaces through advanced additive manufacturing solutions tailored for film & entertainment applications.
Quality and compliance
Production-ready fabrication for on-set use
Entertainment builds still need engineering discipline: safe wearable parts, repeatable fit, reliable paint prep, and delivery windows that hold against production schedules.
Production Timeline Reliability
Guaranteed delivery schedules with 24-48 hour rush capabilities to meet critical production deadlines and shooting schedules.
Confidentiality & Security
Comprehensive non-disclosure agreements and secure handling protocols for all project materials and intellectual property.
On-Set Durability Testing
Rigorous stress testing for stunt work, environmental conditions, and repeated handling to ensure props perform throughout production.
Manufacturing Capabilities
Capabilities Engineered for Film & Entertainment
From concept models to production-intent hardware, each workflow is tuned for the precision, repeatability, and engineering confidence that film & entertainment teams demand. Our capabilities span rapid prototyping with sub-millimeter accuracy, complex geometry optimization for weight reduction, and low-volume production with full material traceability — giving engineering teams the speed to iterate faster and the data to qualify parts with confidence.
Precision Prop Fabrication
Manufacture functional and non-functional props with complex geometries and fine details. From sci-fi weapons and tools to mechanical elements and hero pieces, our technologies deliver exceptional accuracy and surface quality ready for paint and finishing.
Surface detail
0.1mm resolution
Insight 2
Complex internal geometries
Insight 3
Paint-ready surface finish
Insight 4
Mechanical functionality options
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)/Selective Laser Sintering (SLS)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Precision Prop Fabrication
Costume Elements & Wearables
Create lightweight, form-fitting components for costume applications including helmet inserts, mechanical detailing, armor segments, and mask components. Our materials and processes ensure comfort for performers while maintaining visual impact and durability.
Insight 1
Lightweight construction
Insight 2
Custom fit geometries
Insight 3
Comfortable for extended wear
Insight 4
Stunt-ready durability
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)/Selective Laser Sintering (SLS)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Costume Elements & Wearables
Set Dressing & Scenic Elements
Rapidly produce scaled pieces for futuristic or historical sets, architectural details, and custom scenic elements. Cost-effective alternative to traditional fabrication methods with the flexibility to accommodate last-minute design changes.
Insight 1
Large-scale production capability
Insight 2
Rapid design iteration
Insight 3
Cost-effective vs traditional methods
Insight 4
Historical accuracy reproduction
Relevant technologies
Stereolithography (SLA)/Selective Laser Sintering (SLS)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)
Material options
Set Dressing & Scenic Elements
Mechanically Functional Components
Engineer working mechanisms including hinged joints, rotating assemblies, drone enclosures, and interactive elements. Manufactured with tight tolerances using engineering-grade materials to ensure reliable performance during filming.
Insight 1
Tight mechanical tolerances
Insight 2
Engineering-grade materials
Insight 3
Reliable on-set performance
Insight 4
Interactive functionality
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Mechanically Functional Components
Iterative Concept Prototyping
Support rapid design iteration with fast turnaround visual and test models. When design changes happen quickly during pre-production, our team delivers updated prototypes within days to keep projects on schedule.
Insight 1
Same-day design changes
Insight 2
Visual and functional testing
Insight 3
Multiple material options
Insight 4
Rapid iteration cycles
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)/Selective Laser Sintering (SLS)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Iterative Concept Prototyping
Legacy & Reproduction Work
Recreate iconic props and costume elements from existing references, reverse-engineer vintage pieces, and produce accurate replicas for sequels, remasters, and special editions. Maintain authenticity while improving functionality.
Insight 1
Authentic reproduction capability
Insight 2
Reverse engineering services
Insight 3
Archive-quality documentation
Insight 4
Enhanced functionality options
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Legacy & Reproduction Work
Precision Prop Fabrication
Case Studies
Film and Entertainment Outcomes
Recent prop and costume builds showing how printed parts moved from concept art into on-camera production assets.
Case Study
Come to Daddy - Receipt Spike Prop
Complex prop fabrication for Come to Daddy, a black comedy feature starring Elijah Wood. The character has a cast-iron receipt spike stabbed through his cheek - an effect requiring real props rather than CGI. The prop was designed in two components: a false cheek holding the base of the receipt spike, and a spike mounted on a dental appliance inside the mouth. Since it had to hang off his face, the base needed to be extremely lightweight, durable, easy to paint, and completed fast - making it perfect for Accura 25 SLA 3D printing.
Key outcomes
Extremely lightweight design achieved
Durable for repeated takes
Paint-ready surface finish
Fast turnaround for production schedule
Case Study
Superhero Film Costume Integration
Developed lightweight armor components for major superhero production, integrating LED lighting systems and mechanical articulation points. Achieved 40% weight reduction compared to traditional fabrication while maintaining visual impact and performer comfort throughout extended filming.
Key outcomes
40% weight reduction achieved
Integrated LED lighting systems
Mechanical articulation points
Extended wear comfort maintained
Material Library
Film & Entertainment-Grade Materials
Qualified materials selected for performance, certification requirements, and repeatable production in film & entertainment environments.
SLS
SLA Resins
Film & Entertainment grade
High-detail resin printing
- Smooth surface finish
- Perfect for film props
- Excellent detail resolution
View Material Details
SLS
Nylon PA12
Film & Entertainment grade
Durable functional props
- Production-like properties
- Impact resistant
- Professional appearance
View Material Details
SLS
TPU
Film & Entertainment grade
Flexible costume elements
- Wearable prop components
- Realistic texture
- Safe for skin contact
View Material Details
FDM
Carbon Fiber Nylon
Film & Entertainment grade
Lightweight structural props
- High strength-to-weight ratio
- Professional appearance
- Excellent for hero props
View Material Details
SLS
Clear Resin
Film & Entertainment grade
Crystal clear transparency
- Glass-like appearance
- Perfect for lenses
- Optical-grade clarity
View Material Details
SLS
ABS
Film & Entertainment grade
Impact resistant props
- Easy post-processing
- Paint-ready surface
- Durable for action scenes
View Material Details
Explore Our Complete Material Matrix
Compare certifications, mechanical properties, and application fit across our full portfolio before locking your production material stack.
Manufacturing Technologies
Proven Technologies for Film & Entertainment
Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.
Stereolithography (SLA)
Build Volume1500 × 750 × 550 mm (59 × 29.5 × 21.7 in)
Layer Height0.025 - 0.150 mm
Materials5 available
Highest DetailSmooth Finish+2 more
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Selective Laser Sintering (SLS)
Build Volume340 × 340 × 600 mm (13.4 × 13.4 × 23.6 in)
Layer Height60 - 120 microns
Materials4 available
No Support StructuresCost-Effective for Complex Parts+4 more
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Fused Deposition Modeling (FDM)
Build Volume914 × 609 × 914 mm (36" × 24" × 36")
Layer Height127 - 330 microns
Materials7 available
Large-Format PrintingCost-Effective Manufacturing+5 more
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PolyJet Matrix (PolyJet)
Build Volume380 × 284 × 380 mm (15 × 11.2 × 15 in)
Layer Height0.028 mm (28 microns)
Materials3 available
Multi-Material IntegrationVariable Shore Hardness+4 more
Learn More
Need help selecting the best process?
Our application engineers can map your requirements to the right technology, material, and finishing workflow before you commit to a build.
Start a quote
Ready to Transform Your Film & Entertainment Manufacturing?
Upload your CAD files for an instant quote or speak with our application engineers about your specific requirements.
- Instant pricing with automated manufacturability analysis
- Production workflows built for repeatable quality
- Engineering support from prototype to production
Upload your CAD file
STL, STEP, OBJ, 3MF supported
Instant pricing and manufacturability feedback
- 6
- Manufacturing technologies
- 50+
- Engineering materials
- 1-500+
- Part quantities