

In 2023 we set out to solve a problem:
"What to do with props/sets at the end of a production?"
Industry Changes
BAFTA albert introduced mandatory carbon tracking and green certification, incentives and schemes such as London's Green Screen program and BFI-backed strategies are becoming available, sustainability is becoming a hot topic across all production stages.
Our Goals
1) Reduce carbon cost
2) Reduce waste
3) Find a circular solution

Rusty Design Sustainable Props and Sets
We design and build props and scenery with sustainability in mind. Using our cutting-edge in house technology, we help productions reduce costs, cut carbon, and avoid waste, all without compromising on creativity or quality.
Our Method
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Cutting Out Material Waste
Traditional methods cut shapes from large blocks of material, leaving offcuts that end up in the skip. Our large-scale 3D printers build objects layer by layer, meaning no waste from cutting.
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Less Material, Lower Costs
Our experts can design mostly hollow props, which dramatically reduces the amount of material needed—saving you money on materials and on transport, labour, and storage.
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Cheaper Disposal
Hollow props can be easily crushed or broken down, fitting into far fewer skips at the end of a shoot. That means less money spent on waste collection, and fewer skips clogging your backlot.​
​Cutting Carbon
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Plant-Based Plastics, Not Oil
Most of our printing uses PLA, a plastic made from corn or sugarcane, not fossil fuels. It’s a renewable, plant-based material that has a much lower carbon footprint than traditional plastics.
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Recyclable & Circular Design
We’re already reclaiming used PLA and turning it back into usable material—bringing circular production to life. While we're still testing how many times it can be reused, even one extra life cuts material needs in half.
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Turning Old Props into Useful Ingredients
We’ve also developed a method to break old PLA props down into lactic acid, which has potential use in eco-friendly cleaning products or other industries. It’s even safe to return to the environment when diluted properly.​
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Summary: The Benefits for You
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01
LOWER MATERIAL COSTS
Hollow 3D prints use less and waste less material
02
REDUCED CARBON FOOTPRINT
Renewable PLA as a primary material and limited offcut waste
03
CHEAPER WASTE DISPOSAL
Props and sets crush down smaller requiring less skips
04
SUPPORT SUSTAINABILITY
Making recycled prints and chemical recovery for circular use viable
