Bringing Larry Lumen to Life: A Behind-the-Scenes Look

MSA were recently challenged with creating a life-size Peli 3415, with plans to use it on exhibition stands, almost as a company ‘mascot'. The idea was simple: create a larger-than-life, cartoon-style Peli 3415 Z0 torch. The challenge was anything but. This post will delve into MSA’s process when transforming a cartoon design into a tangible creation.

Overcoming the Scale Challenge

The first hurdle was size. The brief called for an average-sized man, around 5’8”. To accurately capture the intricate details of the torch, we opted for 3D scanning the actual 3415 torch. Then the scan was scaled up from its current 6.5 inches to 5 foot 8 inches.  

From Digital to Foam: The Manufacturing Maze

Turning a digital model into a physical foam structure left plenty of questions that had to be addressed. Factors like machinery capabilities, assembly methods, center of gravity and maintaining the cartoon aesthetic all needed careful consideration.

Breaking it Down

To manage the complexity, we divided the torch into sections, similar to Lego bricks. This simplified the manufacturing process while preserving intricate curves. Our 5-axis waterjet and CNC machines were instrumental in cutting out these sections with precision.

Strength and Stability

Foam is flexible, so reinforcing the structure was crucial. Internal plastic pipes added rigidity while maintaining the cartoonish look. Careful consideration of the center of gravity prevented our towering torch from toppling over.

The Finishing Touches

Creating the head and feet presented unique challenges. The head required careful shaping to mimic the original torch's curves, while the feet needed to be both visually appealing and structurally sound. By matching the foot area to the head, we significantly improved stability.

Modular Design for Easy Assembly

To simplify production, transport, and assembly, we opted for a modular design. Breaking the torch down into manageable sections made the process more efficient and reduced the risk of errors.

Bringing Larry to Life

With the design complete and production drawings in place, our team assembled the first prototype. A few final touches, like foam hands and custom lettering, brought Larry to life.

Creating Larry was a journey filled with challenges and triumphs. We're incredibly proud of the result!

Want to learn more about MSA Foam Capabilities?

Get foam-midable results, with MSA’s range of custom foam capabilities. Now we’ve shown you what we can do, let’s discuss your requirements! Enquire today, and a member of the team will be in touch.  

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