Props and Set Fabrication
Large-Format Set Design
3D Print the
Future of Your Sets.
Reduce your material costs by up to 80% and deliver your projects in record time with industrial pellet-based technology.
Impresoras 3d
Set Design – Large-Format Props – Sculptures – Theatrical Sets
—— The real problem
Traditional methods are costing you projects
Every large-format monolithic prop made with EPS, fiberglass or polyurethane foam has the same problems. And they all affect your margin.
Unpredictable manufacturing time
The artisanal work of cutting, assembling and finishing large pieces can triple the estimated time. A delay in a theatrical production has no second chance.
Scarce specialized labor
EPS and large-format sculptors with experience are increasingly difficult to hire. Dependency on a single person limits your delivery capacity.
Uncontrolled material cost
Polyester resin, fiber and finishes add up. On pieces from 1.5 to 3 meters, material cost can exceed 40% of the total prop budget.
Your workshop working to store, not to produce
EPS blocks, fiberglass molds and foam panels take up space you need for production. A large job can leave your workshop unusable for weeks — full of material that generates no value until it becomes a prop. With FGF, the project lives in a digital file. No warehouse, no bulky material inventory, no wasted space.
Real comparison
EPS vs. fiberglass vs. pellet printing
Reference prop: humanoid figure at 2 meters, production of 3 units.
| Criteria | EPS + finish | Fiberglass | FGF Printing (Fused Form) |
|---|---|---|---|
| Time per unit | 8–14 days | 6–12 days | 2–4 days |
| Material cost | High + variable | High + toxic | Controlled industrial pellet |
| Exact replication | ✗ Manual, varies | ✗ Costly mold | ✓ Digital, identical |
| Surface finish | Requires sculptor | Requires extensive sanding | Direct priming |
| Design modifications | Start over from scratch | New mold required | Edit file and reprint |
| Pieces up to 1 meter without seams | ✗ | ✗ | ✓ P1300 prints monolithically |
| Toxicity / ventilation | Moderate | High — PPE required | Low — thermoplastic pellets |
| Storage space | High — EPS blocks and molds | High — molds + materials | None — the project is a file |
Next step
How much would your company specifically save?
These numbers are based on the average case. Use the interactive calculator to project real savings based on your project volume and current costs.
Print your parts and prototypes with Fused Form.
Access a wide range of industrial-grade materials to produce your prototypes. Our expert team guides you through the entire process using our full fleet of 3D printers.
Who this is for
Applications on stage
Theater sets and scenography
Columns, arches, large-scale architectural elements. Printed in modular parts for easy transport and quick assembly between performances.
Theater & OperaFilm and television props
Exact replicas of vehicles, creatures, weapons and set dressing. Complex geometry straight from the 3D model to the set — no manual sculpting.
Film & TV ProductionSculptures and public art
Large-format figures, busts and sculptural pieces for museums, galleries and public spaces. Paintable, long-lasting finish material.
Art & MuseumsEvents and brand activations
Temporary installations, booths, corporate mascots and brand experience structures. High production speed for tight deadlines.
Events & BTLTheme parks and attractions
Durable outdoor theming, creatures and decorative structures that require resistance to weather conditions.
EntertainmentTheater and design schools
Scenic production workshops that need to fabricate pieces quickly on an academic budget. Recycled pellet reduces the cost per print hour.
EducationLearn more
Articles to understand the technology
Main guide
EPS vs. pellet printing: what is the real cost of manufacturing a large-format prop?
Detailed cost comparison of materials, labor time and replication capacity for scenic projects from 1 to 3 meters.
↗Technique
How to print a 90 cm monolithic sculpture without visible seams
The P1300 allows printing single pieces that in other technologies require assembly.
↗Use case
Real ROI: from the first printed prop to recovering your machine investment
How many projects you need to amortize the P600+ depending on your client type.
↗Ready to go beyond theory?
See real use cases, compare with your current situation and download the case study with concrete figures.
Free resources — no sign-up required
Direct download, no forms
Two resources to help you arrive well-prepared before speaking with a specialist.
PDF · Technical guide
Pellet materials guide for scenography
- →PLA, ASA, PETG and composites comparison
- →Cost per kilo table for Mexico, Colombia and the USA
- →Recommended finishes for theatrical painting
- →Specification checklist for quoting
PDF · Practical guide
Practical guide for set designers and art directors: from sketch to real object in 4 steps
- →How to get a 3D file of your piece — even if you're not a designer
- →What to do when your piece is bigger than the printer
- →The key decisions to make before hitting print
- →How to turn the printed piece into a stage-ready prop
Ready to take the next step?
Request your personalized quote. A specialist will prepare a proposal tailored to your type of projects in under 24 hours.
Latest news
Fused Form delivers a P600 pellet 3D printer to Penn State University
Fused Form Collaborates with BMW and Technical University of Munich on Research Paper
