Vacuum Forming In the Movies: Flix Fx

Marc Pollack of Flix FX, Inc in North Hollywood, CA has been producing special effects/props for use in TV, commercials, movies, events and the music industry for the past 21 years. They’ve branched out to include a new patent pending process that will expand the horizon of what can be done with vacuum forming by being able to digitally pre-print a registered graphic image on the plastic prior to the forming process.  It creates a finished product that is useable in POP, theatrical, retail advertising and many other applications.

Step 1: Digital File

Step 2: Digital 3D Sculpting

Step 3: Routed Precision Board Plus





Step 4: The Final Result








Flix FX also known as 3D Vacuprint, has been using Precision Board Plus PBLT-10 on the majority of their 3D relief carvings. They start with a 2D image and create a 3D file through specialty software. The 3D file is converted to a file that is readable by the CNC router, which cuts the 3D profile in PBLT-10. At this time, a 2D image is printed on plastic, using proprietary software to compensate for distortion on the finished form. The final step is to register the form under the plastic and vacuum form it.

Marc says, “We can get 50-150 pulls from the PBLT-10 and when we need more than that, we’ll switch to a higher density or make a fiberglass mold.  Just like anything else it has its purpose and where it fits.  Precision Board Plus is our material of choice, and is a vital step in the creation of our product.”

For one of their recent projects, the Flix FX team created Toyota Drones for a television commercial.  The forms for the drones were machined from PBLT-10, the carbon fiber fin was processed by 3D Vacuprint.  The form (drone) was then vacuum-formed and used in the commercial that was played for NASCAR audiences.

Watch the video clip. If you would like more information, give Marc a call at (818) 765-3549. Take a look at their web sites to see the diverse projects for both Flix FX and 3DVacuprints.