ForgeLabs Advanced ManufacturingForge Labs

3D Printed Movie Props and Costume Parts for Film & TV

Hero props, costume components, creature parts and set hardware for productions working against hard delivery dates, with paint-ready surfaces that hold up on camera and on set.

  • Next day turnaround for productions on tight schedules.
  • Paint-ready SLA surfaces with detail down to 0.1 mm.
  • Matching hero, stunt and backup copies from the same file.
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Film & Entertainment 3D Printing Solutions
Film & Entertainment Overview

From hero props to repeat production copies

Film and television productions need parts that look right on camera, fit performers correctly and arrive on schedule, often as several matching copies. We have supported productions across North America with hero props, replicas, costume details, creature parts, working mechanisms and repeatable set components, using SLA, SLS, MJF, FDM and PolyJet. Additive manufacturing shortens fabrication time while keeping the surface quality and durability that production use demands. Our Vancouver facility works directly with studios and effects shops, under full NDAs when a project is confidential, and has worked on productions including Altered Carbon, Power Rangers and Sonic the Hedgehog.

Where additive creates leverage

Ready when the shooting schedule moves

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

  • Get next day turnaround when the shooting schedule moves.
  • Build complex prop geometry without tooling constraints.
  • Make lightweight builds for wearable props and costume pieces.
  • Specify durable nylon for stunt work and heavy handling.
  • Change designs mid-production without tooling, and reprint matching copies and backups from the same file.
  • Keep projects confidential with full NDAs and secure handling of files and parts.
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Film & Entertainment Manufacturing Process 1
Film & Entertainment Manufacturing Process 2
Film & Entertainment Manufacturing Process 3
Film & Entertainment Manufacturing Process 4
Quality and compliance

Production-ready fabrication for on-set use

Entertainment builds still need engineering discipline: comfortable wearable parts, repeatable fit across copies, reliable paint prep, and delivery dates that hold against production schedules.

Wearable material selection
Material selection and fit checks for wearable parts, with lightweight nylon and TPU 88A that carries supplier skin-contact test data.
Production timeline reliability
Committed delivery dates, with next day turnaround for critical production deadlines and shooting schedules.
Confidentiality and security
Non-disclosure agreements and secure handling protocols for all project files, parts and intellectual property.
Durable materials for handling
Material selection for stunt work and repeated handling, using impact-resistant nylon, ABS and carbon-fibre nylon.
Paint-ready finishing
SLA props arrive with supports removed and surfaces sanded for your paint team. Nylon parts can be dyed black or painted.
Matching copies and repeat orders
Hero, stunt and backup copies print from the same file, and repeat orders are placed from your order history.
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Manufacturing Capabilities

Props, Costumes, Set Dressing and Replicas

The film and television parts we make most often, with the processes, materials and material data behind each.

Precision Prop Fabrication
Precision Prop Fabrication

Hero and production props

Precision Prop Fabrication

SLA builds functional and non-functional props with complex geometry, internal features and fine detail, from sci-fi weapons and tools to mechanical elements and hero pieces. Surfaces come off the printer accurate and smooth, ready for paint and finishing. Hero, stunt and background copies print from the same file, so they match, and backups can be reprinted when a part breaks on set.

Typical parts
Hero props, weapons and tools, matching stunt and backup copies
Key properties
0.1 mm minimum feature; ±0.25% (min ±0.25 mm)
Material data
Accura 25 Shore D 80; sandable and paintable SLA resins
Materials
Accura 25 (SLA)Accura Xtreme White 200 (SLA)
Costume Elements & Wearables
Costume Elements & Wearables

Costume and armor

Costume Elements & Wearables

SLS and MJF nylon and flexible TPU produce lightweight, form-fitting helmet inserts, armor segments, mask components and mechanical detailing. Parts are light enough for extended wear and durable enough for stunt work while keeping their visual impact, clear Accura ClearVue visors can be polished to optical clarity, and repeat sets can be printed for stunt performers and backups.

Typical parts
Helmet inserts, armor segments, mask components, clear visors
Key properties
PA12 0.93 g/cm³; TPU 88A 270% elongation (XY)
Material data
TPU 88A ISO 10993-5/-10 and OECD 439 tested
Materials
Nylon PA12 (SLS)HP High Reusability PA12 (MJF)TPU 88A (SLS)Accura ClearVue (SLA)PolyJet
Mechanically Functional Components
Mechanically Functional Components

Mechanisms and practical effects

Mechanically Functional Components

Working mechanisms such as hinged joints, rotating assemblies, animatronic components and interactive elements are built in engineering-grade nylon and thermoplastics. Tight mechanical tolerances keep them working reliably through filming.

Typical parts
Hinged joints, rotating assemblies, animatronic components
Key properties
±0.3% (min ±0.3 mm) SLS; PA12 50 MPa tensile
Material data
PAHT-CF 92 MPa tensile (X-Y), HDT 170 °C
Materials
Nylon PA12 (SLS)PAHT-CF Carbon Fiber Nylon (FDM)ABS (FDM)
Set Dressing & Scenic Elements
Set Dressing & Scenic Elements

Set pieces and scenic detail

Set Dressing & Scenic Elements

FDM, SLA and SLS produce scaled pieces for futuristic or historical sets, architectural details and custom scenic elements, with historical detail reproduced accurately. Large-format machines build big pieces in fewer sections, printing is a cost-effective alternative to traditional fabrication, and last-minute design changes need no new tooling.

Typical parts
Scenic elements, architectural details, scaled set pieces
Key properties
Build size to 914 × 609 × 914 mm (FDM), 1500 × 750 × 550 mm (SLA)
Material data
ABS HDT 104 °C at 0.45 MPa; paint-ready surface
Materials
ABS (FDM)Accura 25 (SLA)Nylon PA12 (SLS)
Forge Labs technician applying a bronze finish to a replica lantern beside an unpainted 3D-printed copy.
Forge Labs technician applying a bronze finish to a replica lantern beside an unpainted 3D-printed copy.

Replicas and reproductions

Legacy & Reproduction Work

We recreate iconic props and costume elements from existing references, reverse-engineer vintage pieces, and produce accurate replicas for sequels, remasters and special editions. Reproductions keep their authentic look while gaining function, and files are kept for future reprints.

Typical parts
Replica props, sequel and special-edition pieces
Key properties
Reverse engineering from references; 0.1 mm SLA detail
Material data
PolyJet 0.028 mm layers; Agilus30 Shore A 30–95
Materials
Accura 25 (SLA)Agilus30 (PolyJet)
Iterative Concept Prototyping
Iterative Concept Prototyping

Pre-production concepts

Iterative Concept Prototyping

Fast visual and test models support design iteration in pre-production. When designs change quickly, updated prototypes can turn around next day, in several material options, so the final props stay on schedule.

Typical parts
Concept models, visual and functional test pieces
Key properties
Next day turnaround; rapid iteration cycles
Material data
SLA, SLS, FDM and PolyJet material options
Materials
Accura 25 (SLA)Accura ClearVue (SLA)PolyJet
Case Studies

Film and Entertainment Outcomes

A prop build that moved from concept into an on-camera production asset.

Come to Daddy Receipt Spike: A 3D Printed SLA Movie Prop

Case study

Come to Daddy Receipt Spike: A 3D Printed SLA Movie Prop

Prop fabrication for Come to Daddy, a black comedy feature starring Elijah Wood. His character has a cast-iron receipt spike stabbed through his cheek, an effect that called for real props rather than CGI. The prop was designed in two components: a false cheek holding the base of the spike, and a spike mounted on a dental appliance inside the mouth. Because the base hung off the actor's face, it had to be extremely lightweight, durable, easy to paint and finished fast, which made it a fit for Accura 25 SLA 3D printing.

Key outcomes

  • Extremely lightweight design achieved
  • Durable for repeated takes
  • Paint-ready surface finish
  • Fast turnaround for the production schedule
Read the Come to Daddy case study
Manufacturing Technologies

3D Printing 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.

Not sure which process fits? Our application engineers map your requirements to the right technology, material and finishing workflow before you commit to a build.

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Material Library

Materials for Film Props and Costumes

Detailed resins for hero props, nylons and TPU for wearable and stunt parts, and thermoplastics for larger set pieces. Compare full properties on each material page.

Explore the complete material matrix. Compare certifications, mechanical properties and application fit across the full portfolio before locking your production material stack.

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Ready to Manufacture Your Film Props?

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
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STEP, STL, OBJ, 3MF and IGES supported

Manufacturing technologies
6
Engineering materials
50+
Part quantities
1-500+