Halloween Clown

When Ralph Court Gardens in Bromyard approach us, 9 out of 10 times it is for something completely out of the box and bespoke.
It's great to work with a customer who has no set limitations and the possibilities really are endless.

The Brief

Stephen from Ralph Court approached us a few months before Halloween and his brief was "We need a 3D clown, 3m high and 4m wide to use for the entrance of our haunted tunnel". We knew this was an ideal opportunity to put our CNC machine to good use and to experiment using a new product called 'Styrofoam'.

The Process

Once we had found the clown image we wanted to base our idea on we created a 3D model using CAD. Our CNC router then began to carve 8 layers of 50mm thick Styrofoam taking 50 hours of machine time! When all the layers were complete we set about pinning and bonding them together. This was then all sealed and hand painted by our talented team.

The Solution

We were really pleased with the end result and how it all came together and the team got a real buzz from using their different skill sets and doing something so different. We can't wait to see what Ralph Court have under their sleeves next...

Halloween Clown
Halloween Clown
Halloween Clown

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