SUSTAINABLE LARGE-SCALE FABRICATION & ENGINEERING

Rusty Design designs and manufactures large-scale 3D printed props, scenic elements, prototypes, and custom fabrication systems from our workshop in South Wales.

Patent-pending technology. Supported by Media Cymru and Innovate UK.

TWO SPECIALIST SERVICES.
ONE ADVANCED MANUFACTURING PLATFORM.

Our work sits at the intersection of design, engineering, fabrication, and sustainable production. We build our own large-format 3D printing systems in-house, then use that technology to deliver practical, lightweight, lower-waste solutions for creative and technical clients.

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Props & Scenic

Sustainable prop fabrication and scenic builds for film, TV, events, and immersive experiences. From hero props to set sections, we combine large-format 3D printing with traditional finishing and prop-making craft.

EXPLORE PROPS & SCENIC

Engineering & Innovation

Prototyping, custom machines, additive manufacturing systems, and technical problem-solving for clients who need something developed, tested, or built.

EXPLORE ENGINEERING

BUILT FOR FILM, TV, AND EVENTS

Rusty Design Props helps productions create large, lightweight, detailed props and scenic elements with less material waste than many traditional fabrication methods. Our large-scale 3D printing process is ideal for oversized forms, repeatable components, organic shapes, and fast development cycles.

Large-format 3D printed props
Scenic sections and set elements
Lightweight hollow PLA structures
Finishing, painting, and surface treatment
Sample development and production support

VIEW PROPS PORTFOLIO

PROPRIETARY LARGE-SCALE 3D PRINTING TECHNOLOGY

We design, build, and program our own large-format 3D printers. This gives us direct control over scale, material use, print strategy, and production workflow — allowing us to create objects that would be difficult, slow, or wasteful to make using conventional methods alone.

Our material and composite development work is currently patent pending.

EXPLORE OUR TECHNOLOGY

LOWER-WASTE FABRICATION FOR LARGE OBJECTS

Our approach uses PLA-based large-format 3D printing to create hollow, lightweight structures that can reduce unnecessary bulk and material use. We are also developing in-house recycling and degradation research around PLA, with workshop energy supplied through an Octopus Green Tariff.

READ ABOUT SUSTAINABILITY

SELECTED WORK

A selection of projects across props, engineering and R&D

ENGINEERING PORTFOLIO

PROPS PORTFOLIO

An incredible team of engineers working in a range of very exciting areas. Super knowledgeable but keen to learn more and test that out in new areas. The workshop is adaptable to meet the needs of their work to deal with both volume and scale of projects. An exciting team doing exciting things!

Joe, PDR

I recently worked with Rusty Design on a new product design and prototype they did an exceptional job. Their designs from our conceptual drawing was first class, they have a keen eye for detail. I highly recommend their services to anyone in need of top-quality design/porotype work.

Andrew, UK

I’ve had a unique experience of being both a supplier and then client of theirs. Approachable and knowledgeable group offering some very high tech and innovative solutions.Always willing to go the extra mile and have gone above and beyond in turning things around super quick to help me with a tight deadline.

Kristian, Prop Maker & Artist

INNOVATION-LED FABRICATION FROM WALES

Rusty Design has developed from an engineering and prototyping company into a specialist large-scale fabrication studio. Our work has been supported by Media Cymru and Innovate UK, helping us adapt our technology for sustainable production in film, TV, and events.

These are just some of out clients, partners, and funding bodies.