Project Overview
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Weight & Material: Lightweight steel construction (under 100 lbs).
Manufacturability: Designed for easy fabrication without specialized machinery or processes.
Simplicity: Utilizes the simplest geometry possible to minimize build complexity.
Portability: Modular design allows for easy disassembly, storage, and transportation.
Structural Integrity: Engineered to fully support all components of the statue.
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Design & Analysis: Conducted mechanical and 3D model analysis for statue frame design and integration.
Research & Development: Led R&D efforts to iterate and optimize structural solutions.
Fabrication & Tooling: Designed custom tooling and executed hands-on fabrication, including welding, grinding, and cutting.
Quality & Documentation: Performed strict QC inspections and maintained comprehensive documentation for all construction processes.
Operations: Managed material sourcing and procurement.
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Structural Integrity: Engineered to meet a 5:1 safety factor.
Budget Constraint: Raw material costs restricted to $1,000 or less.
Timeline: Strict one-month project turnaround.
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Proportional Challenges: Non-human character designs feature unique body proportions, complicating structural frame development.
Geometric Complexity: Rolling geometries are frequently required to provide multi-planar support, presenting significant fabrication challenges.
CAD model of a statue's support frame. The structure was designed for straightforward fabrication and disassembly while maintaining high strength and a low center of gravity.
A custom cutting guide designed for accurately marking and visualizing unorthodox joint angles on pipes.
Shielded Metal Arc Welding (SMAW) utilizing a 7018 electrode on 1/8-inch carbon steel.
Mock-up featuring strategic cutaways to visualize internal frame positioning and structural load distribution within the display piece.
In-progress view of a life-size Grunt display piece, showing 3D-printed armor and exterior components being fitted directly around the completed structural core frame. (Credit: Ethan Wayne)
In-progress capture of the core sculpture, highlighting female connection points integrated for modular limb attachment and transportability. (Credit: Ethan Wayne)
The video showcases the immense strength of good welds and steel, supporting the weight of a full grown adult man (200LBS +) while weighing less than 50lbs. (Ethan Wayne and Gari Jimenez pictured)
Simple High Strength Frames
Preview of the Arbiter and Grunt statue project.
Developed as part of an official commission for Halo Studios. The finished statues are slated for full public display at the upcoming Halo Fest and will subsequently join the collection at the Halo Museum.