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Fabrication Services

Fabrication Services
crafting matter.

The Specialists Ltd combines a world-class team of artists and fabricators along with cutting edge technology to deliver quality solutions to the most complex projects.

From the design phase to the completion of a project, our fabrication team works closely with our clients to create custom solutions to difficult problems.

Our Sub-specialties

CONCEPT DESIGN . MOLDING . SCULPTING . PROSTHETICS . 3D DESIGN & PRINTING . ELECTRONICS . WOOD . METAL . ROUTING . PAINTING . FINISHING

Concept Design

The Specialists Ltd’s designers are here to help with creative design options for all of your projects. We provide a wide range of visual solutions, from 2D renderings to interactive 3D models, helping your project go from the notebook or script to the real world.
  • Hand-drawn illustration
  • Schematic drawings with notations
  • CAD models
  • Blueprints

Molding

At The Specialists Ltd, the molding department has some of the most highly skilled sculptors and mold makers working in the industry today. We mold and cast in a variety of densities and weights, in almost any material, to best suit your needs, whether it is for stunts or hero close-ups.
  • Custom durometers
  • Breakaway stunt props
  • Lightweight props
  • Vacuforming
  • Photo double castings

Sculpting

Our sculpting team is experienced in producing original artwork in clay, silicone, high-density foam, and wood, with the skills to handle a multitude of styles and dimensions. We have years of experience fabricating organic forms, wildlife re-creations, and architectural structures.

Prosthetics

We love making bodies. Our prosthetics artists are experts in creating realistic figures for any application. We offer full human bodies and corpses, individual body parts, autopsy cadavers, and many other practical effects.
  • Full-body casting
  • Individual body parts
  • Bleeding and breathing rigs
  • Applied wounds
  • False teeth
  • Custom blood pools and splatter
  • Hair punching

3D Design and 3D Printing

The future is here. With our 3D design team and industrial-grade 3D printers, we can build custom objects once deemed impossible to fabricate using traditional methods. From geometric objects to organic structures, we can design and print almost any three dimensional shape.
  • CAD drawings
  • Printing in production-grade thermoplastics
  • Printing in clear photopolymer
  • Printing in titanium, stainless steel, aluminum and Kevlar
  • Capable of printing in various durometers within single object
  • 3D laser scanning

Electronics

Our electronics department can fabricate custom electronic props and effects of almost any kind. Our skilled technicians specialize in microcontroller programming, remote (add space) activation,  lighting design, and integrated device fabrication.
  • Programmable and remote activated timers
  • Rigged appliances that remotely turn on/off
  • Electronic flash bulb gunfire simulators

Wood

Whether it’s in the realm of art, architecture, or prop-making, our wood shop can prototype or build anything imaginable. The combination of traditional and digital woodworking equipment, along with our in-house finishing and printing capabilities, allow us full control over the production process, resulting in higher quality and shorter turnaround times.
  • Bamboo weapons
  • Balsa and paulownia wood breakaway stunt objects
  • Wood crates
  • Cabinetry
  • CNC router
  • Duplicator lathe

Metal

Our metal fabrication shop contains a wide selection of machine tools, from the traditional to cutting edge, and is staffed with artisans with decades of experience in art, architecture and mechanical engineering.
  • CNC Machining and Turning
    • *including 5-axis milling
  • MIG and TIG welding
  • Sheet metal forming
  • Sand blasting
  • Machining
  • Fire Bluing
  • Custom Patinas
  • Engraving
  • Custom retractable bladed weapons
  • Custom aluminum sword blades for theatre and film
  • Retractable syringes for medical and entertainment industry

Case Study

The retractable M9 bayonet in our Metal photos collage illustrates the advantage of having so many capabilities under one roof. To make a “stunt kit,” we first laser scan a knife so we can 3D-print the handles.

Our metal shop then builds a sheet metal form to resemble the knife blade, with a retractable spring mechanism inside. The handles are attached to the knife, and the whole thing gets finished in the paint shop. Our mold shop casts the knife in rubber, and affixes a blood pump for the actor to control the flow of blood.

Routing

Our router shop offers both 3- and 5-axis CNC routing capabilities, allowing a wide range of precision cutting. For set decorating, it’s a great way to make lightweight set pieces such as radiators, fire hydrants, and custom-size roll gates. Or, if an actor needs to pick up a large object, we can carve anything up to the size of a motorcycle or tractor tire in foam or rubber. And it’s a great tool for making signage, which adds production value to storefronts and streetscapes.
  • 10'x7'x3' cutting area 5-axis router
    Capable of cutting:
    • brass
    • aluminum
    • wood
    • foam
    • plastics

Painting

With an expert attention to detail, our painting department will add high-definition quality finishes to any project. We assess each piece individually for its specific needs and work with our clients to find the process that’s right for their projects.
  • Faux wood grain
  • Faux marble finish
  • Custom patinas
  • Color matching for large quantity duplication

Finishing

Whether it’s for aesthetics or protection, we offer several finishing techniques within our fabrication department. Our experts know the proper treatment for any project, with a deep understanding of finishes in wood, metal, plastic, foam, and rubber, to name a few.
  • Powder coating
  • Fire Bluing
  • Sand and glass bead blasting
  • Spectra-Chroming
  • Hydro-graphics
  • Mission specific gun painting
  • Metal plating

Highlights from our most recent projects

  • LADY GAGA
  • KIEHLS
  • GQ MAGAZINE
  • CITIBANK
  • THE PUBLIC THEATER
  • CIRQUE DU SOLEIL / PARAMORE
  • VANITY FAIR
  • CADILLAC
  • US ARMY
  • ROLLING STONE
  • COACH
  • GEICO
  • JEFF KOONS STUDIO
  • DISNEY THEATRICAL GROUP
  • MARVEL STUDIOS
  • SATURDAY NIGHT LIVE PRODUCTIONS
  • METROPOLITAN OPERA
  • NEW YORK CITY BALLET
  • GOOGLE
  • DAVID MICHALEK - ARTIST
  • CENTER FOR DISEASE CONTROL
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