Delivering complex, branded product ranges from digital capture to global logistics.

Background - A contemporary fashion brand required a series of bespoke, full-scale candles modeled accurately on their existing footwear range. The project demanded a high degree of realism and structural integrity, transitioning a luxury fashion item into a functional, branded lifestyle product.

The Brief  -The objective was to produce large-volume runs of these intricate items while maintaining the fine details of the original designs. Key requirements included high-fidelity 3D scanning, the development of custom packaging solutions to ensure safe transit for delicate wax items, and the management of large-scale shipping logistics.

Technical Strategy (The Lab) - The development phase focused on accurately capturing the complex geometry of the footwear:

• Hybrid 3D Capture: We utilized 3D scanning to create the primary digital model, which was then hand-sculpted and refined in-house. This allowed us to include functional details, such as the tread of the sole, ensuring the product appeared as a complete 3D object from every angle.

• Packaging Engineering: To mitigate the risk of damage during shipping, we used silhouette renders of the final 3D models to design bespoke packaging inserts. This ensured a perfect fit and provided the necessary protection for the delicate "thin-wall" features of the cast items.

• Material Sourcing: We managed the sourcing and testing of specialized materials to ensure the final product met the brand’s aesthetic and performance requirements.

Mechanical Execution (The Workshop) Transitioning from a single scan to a production run required a robust tooling and scheduling strategy:

• Mould and Support Architecture: We designed and manufactured full 3D silicone moulds, supported by custom-engineered enclosures. These enclosures were essential for maintaining dimensional accuracy across large-volume production cycles.

• Production Management: We oversaw the full production schedule, coordinating the casting process to meet the client’s strict delivery timelines.

• Logistics and Fulfillment: Beyond the build, we managed the secure packing and global shipping of the completed items, ensuring they arrived in gallery-ready condition.

Validation and Result This project demonstrated our ability to manage the complete production pipeline for high-value branded goods. By integrating digital capture, bespoke tooling, and logistical planning, we provided a "turnkey" solution that allowed the client to move from a physical prototype to a distributed product range.

This integrated approach has proven its worth for brands looking to produce complex, cast items at scale without compromising on technical precision or design fidelity.

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