Fonco Studios

The End of the Fiberglass Era Traditional puppet making involves a grueling, multi-step process. You start with a physical clay sculpt, move to a messy **fiberglass mold**, and finally cast foam—a workflow Adam Savage rightly describes as a nightmare. Fon Davis and his team at Fonco Studios are dismantling this archaic pipeline. By moving the heavy lifting into the digital space, they eliminate the need for physical sculpting entirely, jumping straight from concept to functional production hardware. Digital Molds and 3D Printed Solutions At the heart of this optimization is the 3D printer. Since clients already expect high-fidelity 3D models for character approval, Fonco Studios uses that existing data to print the negative space—the mold itself. This isn't just about speed; it's about precision. For the characters **Hick and Doof**, the team integrated 3D scans of a puppeteer's hand directly into the mold design. This ensures the internal cavity of the foam head perfectly fits the performer, a process that used to be a tedious guessing game of manual carving. Practical Finishes and Clever Hacks High-end 3D printing often gets bogged down by surface finishing, but Fon Davis uses a pragmatic approach for puppets. Because the characters are eventually skinned in **felt**, the 3D print's layer lines become irrelevant. The fabric "hides the crime," allowing for faster print speeds and lower resolution without sacrificing the final aesthetic. This practicality extends to outfitting; rather than custom-sewing miniature wardrobes, the studio utilizes off-the-shelf baby clothes. A suit for a 0-3 month infant fits a professional puppet perfectly, saving dozens of man-hours. Rapid Turnaround and the Future This digital-to-physical workflow allowed the team to produce fully realized characters in under a week. By combining 3D printing for complex components like eyes and noses with traditional hand-made touches like custom teeth, Fonco Studios has created a hybrid model that maximizes both artistry and efficiency. It’s a masterclass in using modern tech to bypass the most boring, labor-intensive parts of the craft.