HasLab Insider / Published: September 19, 2018
Read on for our latest updates on Jabba's Sail Barge, including exclusive, behind-the-scenes footage on the tool start for our biggest vehicle yet!
Before we could "cut steel" on the first tooled model, we 3D printed a full-scale grey model. Putting the pieces of the 3D model together allowed us to start thinking about box size and pack-out (coming soon to an update near you!) and make sure that all details were in order before setting sail on the tool start.
We used CAD to plan and design the heavy steel tools that could 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 hulking mold bases which sandwich the cavity and core mold parts together to the actual cutting of the mold parts by powerful rotary bits.
Using a method called Electrical Discharge Machining (EDM), pictured below, we also accounted 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.
Because of the tremendous size of the Khetanna, the steel tools manufactured for this item are some of the biggest we've ever created as a toy manufacturer. The process of getting it just right was a tireless and passionate effort from our incredibly involved team of talented designers, engineers, and manufacturing experts.
Keep an eye out for our next HasLab update coming later this fall!
And as always, May the Force be with you!