Custom Manufacturing Capabilities
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The heart of our FX production facility is our talented and creative staff. Our many specialized tools and technology allow that staff to create wonderful and amazing things.
Cold Molding Room
Silicone, Urethane and Plaster are just a few of the many types of materials that we commonly use to make production molds of our products. The object being molded might be a one of a kind sculpted creature, or maybe it's a common household tool that will be molded to allow a rubber stunt version to be made. We have everything needed to make simple as well as highly complicated molds and the parts that come from those molds. We have great relationships with many materials suppliers and we have a tremendous working knowledge of many types of molding and casting processes. We have a high vacuum chamber system as well as pressure pots to de-gass or pressurize our molds and parts, for defect-free castings.
Hot Casting Room
Inside our hot room is where all of our breakaway glass products are manufactured. This specially built room contains the material as well as special heating systems that are needed to pour the liquid plastic into molds that create everything from breakaway beer bottles to smashable kitchen windows to breakaway taillights. Only our specially trained employees are allowed in this room where our proprietary process for the manufacture of our breakaways, as well as the work with all other hot plastics is carried out.
Full Wood & Metal Shop
We have a fully stocked wood shop that allows us to create our fine breakaway furniture as well as a myriad of custom projects. Some of the larger tools that we have available for use by our artists, are band saws, router tables, table saws, planers, lathes and an assortment of grinders, sanders and smaller hand tools. In addition to the woodworking tools, we have a selection of metal working tools, such as welders, cutters, mills, drills and metal lathes that allow us a great degree of flexibility when working on metal based projects. Our wide variety of in-shop tools keeps your project completely in-house for the duration of the build and allows us to complete the project quickly and inexpensively.
Large Roto-Cast Machine
Our roto-cast machine allows us to fabricate a wide range of hollow-shelled items. Custom built for our needs, this large machine can spin a mold in every direction, which allows plastic or other material to evenly coat the inside cavity of the mold. Our gold bars, and many of our unbreakable props are types of objects that utilize this system. Small to large hollow molds are mounted into the center of the machine. Plastic resin, breakaway material or even plaster is poured into the mold, then the machine spins on two-axis allowing the material to flow evenly across all the surfaces. The resulting part has little or no seam lines and can be large, yet hollow and lightweight.
Dual Head 3D Printer
3D printing has become a very important part of fabricating objects in the FX industry. The ability to create an object in a computer, and rapidly transform it into a solid object in real life allows almost limitless possibilities. We use this system on many of our custom jobs when we need a intricate, detailed part, quickly and inexpensively. We constantly find new ways to implement this plastic extruding workhorse. Almost any 3D computer file can be input into the machine and using a precision extrusion of plastic filament in several colors, layer by layer the object is printed into reality. NEW 3D PRINTER ON ORDER AND COMING SOON
Large Format Vinyl Cutter
We have the ability to cut a wide range of 2D shapes, letters and other elements from vinyl. Our wide format vinyl cutter is the same type used by many advanced sign shops, and allows us to feed rolls of vinyl and via computer control, precisely cut the vinyl according to the specifications. We not only use this to create vinyl decals and elements for our props, but also to make highly precise stencils when we need to paint something. We can also use this as a large scale plotter to draw large layouts with a pen attachment onto a large roll of paper, allowing us to create plans and patterns for larger pieces, with accuracy and speed.
4 Axis CNC Machine
Our 4 Axis CNC machine has revolutionized our ability to build products efficiently and with amazing precision. We use this machine for a wide range of projects including precise cutting of balsa wood for our breakaway furniture, rotationally turning our Breakaway Baseball bats, as well as creating custom fitted foam packaging inserts to make sure our props get delivered without damage. This CNC can also be equipped with a laser head for high detailed etching and laser engraving on a variety of surfaces. We're finding new uses for this machine and this technology every day. This units support a 48x24x9 inch work capacity.
COMING SOON: Thermoforming Machine
We are currently custom building a vacuum forming machine. This will allow us to heat, stretch and form a variety of plastic over molds to produce, thin, lightweight and durable parts, as well as custom shaped globe, extrusions and lenses. Clear, and opaque plastics of many types can be formed using this machine. Supports a 48"x24" Sheet with a 10" working height.
As you can see we have many types of tools available to create your next effect or prop. These are just a few of the tools and capabilities that NRFX can utilize. Of course, our talented staff are the ones that deserve the real recognition, as they are the ones that make these tools sing and create truly breathtaking art.