Harry Potter, Yoda, Elsa — every day, Gentle Giant Studios brings your favorite characters to life. The team has come a long way since the days of clay sculpting 30 years ago.
Today, they use techniques like 3D scanning, 3D modeling, and 3D printing to streamline iterative processes, analyzing digital results before investing in physical models. Let’s take a look at how Gentle Giant Studios developed their workflow by implementing Magics 3D printing software, achieving the refined 3D models they produce today.
About Gentle Giant Studios
Gentle Giant Studios is a renowned company specializing in 3D-printed models and sculptures, particularly licensed products from major brands like Marvel, Star Wars, DC Comics, and more. They use advanced 3D scanning and 3D printing technology to create highly detailed models and statues that closely resemble popular characters from movies, comics, and games.
In addition to producing collectible models, Gentle Giant Studios also collaborates with film studios and gaming companies to offer 3D modeling services, such as digital model design and actor body scans, for accurate character recreation.
Character model from Inside Out 2 at Gentle Giant Studios (Source: Materialise)
The Challenge
“When I joined, the team was using generic software for automatic fixing,” Jason explains. “This software can make files printable, but it doesn’t help users learn. To get the best results, you need to learn quality prototyping techniques before relying on print preparation software. Software with basic functions doesn’t support that development.”
*Print preparation software is a specialized tool that processes 3D files before printing to ensure they meet the technical requirements of 3D printers and result in accurate final products. It typically includes features like error-checking, model scaling, structural analysis, adding support structures for complex details, and optimizing print placement to save material and print time.
Jason Lopes is no stranger to 3D printing. In fact, he has been using this technology since 2007, and his passion and ambitions for 3D printing continue to grow. When he joined Gentle Giant Studios in 2023, he immediately assessed their 3D printing setup to determine how his expertise could improve the lab.
In addition to the potential to develop 3D printing skills further, Jason also saw an opportunity to speed up workflows and expand digital systems to improve project traceability. “The moment I saw their setup, I said, ‘We need Magics here,’” Jason shares.
What is Magics?
Magics is specialized software developed by Materialise, widely used in additive manufacturing (AM) and 3D printing. It’s a powerful tool that supports print file preparation, model error correction, and optimization of complex details before printing, ensuring 3D files are printed with the highest accuracy. Magics provides many features such as error-checking, model repairs, Boolean operations, and structural analysis to support technicians and engineers in creating high-quality 3D models.
Beyond ensuring the technical quality of print files, Magics also optimizes production workflows with data management and reporting features, helping track parts and detail processing steps for each piece. Thanks to its comprehensive features, Magics has become an essential tool for companies specializing in 3D printing and AM, allowing them to optimize workflows, save time and costs, and improve the quality of the final product.
Jason Lopes and Magics software at Gentle Giant Studios (Source: Materialise)
Learn more: MATERIALISE MAGICS HONEYCOMB STRUCTURE MAKES GEAR 46% LIGHTER
The Solution
Jason is a long-time Magics user—he’s been using the software since version 4 and has always been a passionate advocate. He’s introduced it to every company he’s worked with, and Magics has always made a difference.
“Magics has always been my weapon of choice,” Jason says enthusiastically. “With Magics, I can check for errors, modify parts to make them printable, and complete Boolean operations. But beyond that, it simplifies business aspects as well. For example, I can estimate project costs before implementation.”
Many of Gentle Giant Studios' projects involve large designs for printing and complex files for management. As Jason’s 3D printing projects have evolved alongside Magics, he has found that Magics consistently handles increasing file sizes.
Jason and the model from Inside Out 2 at Gentle Giant Studios (Source: Materialise)
The Results
Introducing well-rounded software like Magics into their workflow made a significant difference. After testing for a period, the team found that data and production preparation was 65% faster with Magics, eliminating bottlenecks and the frustration of waiting for previous software to process large, complex files. With these improvements, they have been able to expand their customer base and take on more diverse projects.
As for advancing 3D printing skills for the team, Jason finds that after just one or two months, they show remarkable progress: “For instance, when I introduce Magics to a new team member, their learning curve increases exponentially. It makes them better at prototyping — a geometry expert — without them even realizing it.”
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