How Innovation Workshop Transformed Prop Making with Robotic 3D Printing

When Innovation Workshop needed to create props for blockbusters like Avatar: The Way of Water, Black Adam, and Transformers: Rise of the Beasts, they faced the same challenge every prop house knows: tight deadlines, complex geometries, and the constant pressure to deliver perfection on budget.

Traditional prop making meant weeks of manual sculpting, molding, and fabrication. But Innovation Workshop found a better way, one that's transforming how the industry thinks about prop production.

The Prop Making Problem Every Studio Faces

Picture this: You've got a last-minute script change that requires a massive set piece or vehicle component for tomorrow's shoot. Your traditional fabrication team is already maxed out on another project, and outsourcing will take weeks, minimum.

"We originally got this robot to animate on set and to lift people and props like cars and stuff like that. So when it's not on set, it was just kind of sitting idle," explains Andrew Hyde, 3D & Robotics Supervisor for Innovation Workshop. "So we started exploring other kinds of processes that we could use in manufacturing."

They looked at traditional methods like foam carving, but ultimately chose large-format additive manufacturing (LFAM). "We ended up going with an additive process just because it's cleaner and quicker."

Why Large-Format Additive Manufacturing is Perfect for Props

Think about what props actually need:

Complex geometries that would be impossible or expensive to machine
Rapid iteration when directors change their minds (and they will)
Custom textures and details that traditional methods can't achieve
Lightweight yet durable materials that won't break during action sequences
Fast turnaround because film schedules wait for no one

Large-format additive manufacturing (LFAM) delivers on all these fronts.

How Innovation Workshop Scaled Up with MDAC

"Everyone's trying to always figure out how to do something better, quicker, cheaper, faster. Usually, you don't get all four of those things. You get a pair," Hyde explains. "With this, we got all four, mainly speed."

The MDAC system they chose came with upgraded motors and optimized gear ratios, allowing them to confidently print at 200 mm/s. The real magic happens when you can print massive props and set pieces that would traditionally require complex multi-part fabrication and assembly, full-size vehicle body panels, architectural elements, or creature suit components in one piece, complete with internal structural features and surface textures ready for paint.

The Workflow Transformation

Traditional Method:

Design and engineer a multi-part assembly (3-5 days)
Sculpt or machine individual sections (1-2 weeks)
Create molds for complex geometries (3-5 days)
Fabricate and cast components (1-2 weeks)
Assemble, weld, and finish (3-5 days)
Total: 3-5 weeks per large prop

MDAC LFAM Workflow:

Design as a single piece in CAD (1-2 days)
Print directly at full scale (1-3 days depending on size)
Minimal post-processing (4-8 hours)
Total: 3-6 days per large prop (85% faster)

"With everything here, we can control how quickly everything goes out, the quality, and we can change things on the fly. Basically, that's why we chose to have it in-house," Hyde explains.

Real-World Applications and Why Massive Dimension

The MDAC Industrial Series handles the full spectrum of production needs: large format capability for full-size components without assembly, material flexibility from lightweight foams to durable engineering plastics, surface quality that achieves complex textures, and rapid prototyping for fit and function testing.

"At the time, we were looking for something that was cost-efficient and could output a rating that we were trying to meet. This one offered that, and it came in a full package," Hyde explains.

The real differentiator wasn't just the technology, it was the support. "We had like amazing support from Massive Dimension with their support team. So anytime we had a question, we had someone to call quickly and get an answer to."

When you're working on films like The Matrix Resurrections, Jungle Cruise, or The Tomorrow War, you can't afford downtime.

The Results

Innovation Workshop's success demonstrates that prop making is evolving, and companies that adapt first will dominate. While competitors struggle with traditional methods, they deliver faster turnaround, better quality with consistent repeatability, lower costs through reduced labor and waste, greater flexibility for last-minute changes, and complete control over production timelines.

If you're in prop making or film production requiring custom fabrication, the MDAC Industrial Series systems are not just 3D printers, it's a complete LFAM production solution designed for professional filmmaking demands.

Innovation Workshop proved it on Hollywood's biggest films. What could your team accomplish with this capability?

Ready to transform your prop making workflow? Contact our team today to learn how the MDAC Industrial Series can upgrade your production capabilities.

Schedule a consultation: contact@massivedimension.com

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