Mark Setrakian and Adam Savage investigate a massive prop hand

17 Year Old Hellboy II Prop Still Amazes

May 30, 2025 by Heidi Ulrich 3 Comments

The AI effects we know these days were once preceded by CGI, and those were once preceded by true hand-built physical props. If that makes you think of Muppets, this video will change your mind. In a behind-the-scenes look with [Adam Savage], effects designer [Mark Setrakian] reveals the full animatronic glory of Mr. Wink’s mechanical fist from Hellboy II: The Golden Army (2008) – and this beast still flexes.

Most of this arm was actually made in 2003, when 3D printing was very different than what we think of today. Printed on a Stratasys Titan – think: large refrigerator-sized machine, expensive as sin – the parts were then hand-textured with a Dremel for that war-scarred, brutalist feel. This wasn’t just basic animatronics for set dressing. This was a fully actuated prop with servo-driven finger joints, a retractable chain weapon, and bevel-geared mechanisms that scream mechanical craftsmanship.

Each finger is individually designed. The chain reel: powered by a DeWalt drill motor and custom bevel gear assembly. Every department: sculptors, CAD modelers, machinists, contributed to this hybrid of analog and digital magic. Props like this are becoming unicorns.

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Gaze Upon Robby The Robot’s Mechanical Intricacy

May 1, 2025 by Donald Papp 7 Comments

One might be tempted to think that re-creating a film robot from the 1950s would be easy given all the tools and technology available to the modern hobbyist, but as [Mike Ogrinz]’s quest to re-create Robby the Robot shows us, there is a lot moving around inside that domed head, and requires careful and clever work.

The “dome gyros” are just one of the complex assemblies, improved over the original design with the addition of things like bearings.

Just as one example, topping Robby’s head is a mechanical assembly known as the dome gyros. It looks simple, but as the video (embedded below) shows, re-creating it involves a load of moving parts and looks like a fantastic amount of work has gone into it. At least bearings are inexpensive and common nowadays, and not having to meet film deadlines also means one can afford to design things in a way that allows for easier disassembly and maintenance.

Robby the Robot first appeared in the 1956 film Forbidden Planet and went on to appear in other movies and television programs. Robby went up for auction in 2017 and luckily [Mike] was able to take tons of reference photos. Combined with other enthusiasts’ efforts, his replica is shaping up nicely.

We’ve seen [Mike]’s work before when he shared his radioactive Night Blossoms which will glow for decades to come. His work on Robby looks amazing, and we can’t wait to see how it progresses.

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The Mysterious And Important Work Of Prop Design On Severance

March 13, 2025 by Dan Maloney 28 Comments

Have you seen Severance? Chances are good that you have; the TV series has become wildly popular in its second season, to the point where the fandom’s dedication is difficult to distinguish from the in-universe cult of [Kier]. Part of the show’s appeal comes from its overall aesthetic, which is captured in this description of the building of one of the show’s props.

A detailed recap of the show is impossible, but for the uninitiated, a mega-corporation called Lumon has developed a chip that certain workers have implanted in their brains to sever their personalities and memories into work and non-work halves. The working “Innies” have no memory of what their “Outies” do when they aren’t at work, which sounds a lot better than it actually ends up being. It’s as weird as it sounds, and then some.

The prop featured here is the “WoeMeter” from episode seven of season two, used to quantify the amount of woe in a severed worker — told you it was weird. The prop was built by design house [make3] on a short timeline and after seeing only some sketches and rough renders from the production designers, and had to echo the not-quite-midcentury modern look of the whole series. The builders took inspiration from, among other things, a classic Nagra tape recorder, going so far as to harvest its knobs and switches to use in the build. The controls are all functional and laid out in a sensible way, allowing the actors to use the device in a convincing way. For visual feedback, the prop has two servo-operated meters and a string of seven-segment LED displays, all controlled by an ESP-32 mounted to a custom PCB. Adding the Lumon logo to the silkscreen was a nice touch.

The prop maker’s art is fascinating, and the ability to let your imagination run wild while making something that looks good and works for the production has got to be a blast. [make3] really nailed it with this one.

Thanks to [Aaron’s Outie] for the tip.

Laser Cut Acrylic Provides Movie-Style Authentication

February 12, 2025 by Tom Nardi 13 Comments

Here at Hackaday, we pride ourselves on bringing you the latest and greatest projects for your viewing pleasure. But sometimes we come across a creation so interesting that we find ourselves compelled to write about it, even if it’s already been hanging around the Internet for years. This may or may not be due to the fact that we just re-watched Crimson Tide, and found ourselves on a self-imposed dive into a very particular rabbit hole…

If you’ve seen Crimson Tide, or the first few minutes of WarGames, you might already know what this post is about. Both films prominently make use of a one-time authentication device which the user snaps in half to reveal a card that has some secret code printed on it — and as it turns out, there are at least two different projects that aim to replicate the props used in the movies.

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Light Brite Turned Sci-Fi Console On The Cheap

January 2, 2025 by Tom Nardi 13 Comments

Generally, the projects featured on Hackaday actually do something. We won’t go as far as to say they are practical creations, but they usually have some kind of function other than to sit there and blink. But what if just sitting still and blinking away randomly is precisely what you want a piece of hardware to do?

That was exactly the goal when [createscifi] set out to dress a Lite Brite up as a futuristic prop. On a technical level, this project is pretty much as simple as it gets. But we appreciated seeing some of the techniques brought to bear on this project, and perhaps more importantly, really like the channel’s overall goal of creating affordable sci-fi props using common components. We don’t plan on filming our own space epic anytime soon…but we like to know the option is there.

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Walkie Talkies, Jedi Style: Building A Communicator

December 13, 2024 by Heidi Ulrich 6 Comments

Playing Star Wars Outlaws sparked an idea with [3DSage]: why not recreate the game’s wrist communicator as a functioning gadget? Inspired by the relatively simplistic design, he and his friend Ben set out to build their own device to take to Galaxy’s Edge in Disneyland. Armed with an arsenal of tools—3D printers, CNC machines, and soldering irons—he aimed to turn imagination into reality.

After ordering multiple walkie-talkies, they meticulously tested each one for audio quality, circuit board size, and compatibility with custom components. The ‘world’s tiniest walkie-talkie’ had potential but demanded creative modifications, including disassembling and resoldering components. They crafted their own circuit board and designed a 3D printed housing to fit both electronics and style. For the finishing touch, they weathered the device with paints and even glow-in-the-dark accents, making it authentic to the Star Wars universe. Even Chewbacca himself gave one a thumbs-up!

Weathering goes a long way towards creating a convincing prop — it can turn a bundle of pipes and some foam blocks into a movie-ready WWII machine gun.

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Magic Cane Is The Secret Behind Lightsaber

June 17, 2024 by Elliot Williams 23 Comments

Everyone has a lightsaber or two lying around the house, but not everyone has a lightsaber that extends and retracts automatically. And that’s because, in the real world, it’s not an easy design challenge. [HeroTech]’s solution for the mechanism is simple and relies on an old magician’s trick: the appearing cane. (Video, embedded below.)

An appearing cane is a tightly coiled up spring steel sheet that springs, violently, to its full length when a pin is released, but they can’t retract while the audience is looking. This is fine for magic tricks, but a lightsaber has to be able to turn off again. Here, an LED strip does double duty as source of glow but also as the cable that extends and retracts the appearing cane spring. A motor and spool to wind up the LED strip takes care of the rest.

There are still a number of to-dos in this early stage prototype, and the one mentioned in the video is a tall order. Since the strip doesn’t illuminate out the sides, the lightsaber has two good viewing angles, and two bad ones. The plan is to rotate the LED strip quickly inside the sheath: an approach that was oddly enough used in the original movie prop, as demonstrated in this documentary. Doing this reliably in an already packed handle is going to be a challenge.

If you’re thinking you’ve seen a magic-cane lightsaber before, well, maybe you saw this video. And if you want a light saber with real lasers, check out this build that brings its own fog machine. Take that, Darth Vader!

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