HasLab TVC Jabba's Sail Barge Prototype

A 12" model was created for DECO design.

The factory used CAD to plan and design the heavy steel tools that would bring all 250 parts of the Barge to life. In the video and images below, you can view the various parts of the tool being made, from forming the huling mold bases wich sandwich the cavity and core mold parts together to the actual cutting of the mold parts by power rotary bits.

Using a method called Electrical Discharge Machining (EDM), they were able to account for the smaller details of the barge (where rotary bits are too big to get all of the intricate detail) by creating a small copper cast of the desired part, then transferring that design to a steel tool that uses a powerful electrical current to cut the shape into the steel.

Here are images of the first 3D model used to develop steel tools for the injection mold process.