Fans of Jaws can now get a closer look at its most iconic creature in a way that was never possible before, thanks to the Formlabs Form 4L. At the Academy Museum of Motion Pictures, a newly created version of the shark “Bruce” is designed not just to be seen, but interacted with.
To make that happen, KNB EFX was brought in to build a smaller scale replica of the original animatronic. The goal went beyond appearance. It had to feel real while also being strong enough to handle repeated movement from hands-on interaction from visitors.
The process started digitally. The original shark was captured using 3D scanning, giving the team a highly accurate base model. From there, the design was scaled down and split into multiple sections, so it could be produced more efficiently.
These pieces, designed with built-in keys for easy assembly, were 3D printed on the Formlabs Form 4L. Once printed, the parts were assembled into a full model, which was then used to create molds and a running core for casting the shark’s outer “skin,” or hollow shell. A separate core was also produced to house the internal mechanical components.
3D printing played a major role throughout the process. The high level of detail made it possible to recreate complex shapes and textures without extensive manual sculpting, while also speeding up production. Many of the printed parts were used both as final components and as master patterns for molding.
Once the internal structure was complete, the cast outer shell was assembled and finished. Painting, sanding, and detailing brought everything to life, capturing the look of the original shark all the way down to the skin texture and teeth. Additional 3D printed elements, including the shark’s teeth, helped complete the final look.
One of the biggest advantages of this approach was speed. The entire project went from concept to finished piece in just a few weeks, something that would have been extremely difficult to achieve using traditional methods alone.
As Greg Nicotero, founder/owner of KNB EFX, puts it, “the level of detail is what really stands out.” Every pore, every tooth, every small detail from the original sculpture can be captured and reproduced exactly, which has been a huge shift in their workflow.
Projects like this show just how much special effects workflows have evolved. 3D printing has become a core part of the process, from early concepts to final pieces, helping teams move faster, stay accurate, and create durable, interactive results that still meet the level of realism audiences expect. If you’re interested in the Form 4L, reach out to our team of experts today.
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