Captain America: The First Avenger (2010)

Between June and September 2010, I worked for Prop Master Barry Gibbs under Supervising Prop Makers Roland Stevenson and Jim Barr on ‘Captain America: The First Avenger’ at Shepperton Studios. My work was mainly in the armoury department helping to make the hero and stunt Hydra assault rifles. My duties included pattern making, detailing, casting and assembly of hero weapons, final paint finishing and effects, some mould making and the assembly of over 60 rubber stunt weapons that we had outsourced to a gun rubber specialist.

Hydra hero weapon

Hydra rubber stunt weapons 

The Edge of Tomorrow (2014)

From April 2012 to February 2013 I worked for Pierre Bohanna on ‘The Edge of Tomorrow’ at Warner Studios in Leavesden. I started as a pattern maker for the prototype development stages of the eco suits which included making the weapon prototypes and armour/helmet components from a low density foam. The prototype armour was then drawn up in Solidworks and 3D printed before being moulded and cast in a strong polycarbonate. I then moved on to making a variety of hero, stunt and set dressing props including drones, bombs, grenades, remote control devices, blood transfusion equipment and transponders. 

Prototype armour

Sculpted in polyurethanefoam

UDF drones

Made from vac formed styrene, injection moulded resin, aluminium and steel.

Drop ship cannons

Made from vac formed styrene, injection moulded resin, aluminium and steel.

Blood transfusion unit

Hand machined in chemiwood before being moulded and cast in resin. Aluminium and resin detailing. 

The screen in an iPod that runs a short movie on a loop.

Transponder (stunt version)

Hand turned in chemiwood with aluminium detailing.

UDF training drone controls

Vacuum cast resin from hand made chewiwood patterns

Remote control bombs

Vacuum cast resin from hand made chewiwood patterns. Detailed with found parts.