Case Studies Case Studies

Case Studies

Special Modeling

01The Order: 1886

Production Background

The model was created as a prop for a promotional video of The Order: 1886, a PS4-exclusive action adventure game.

Our Passion

We paid meticulous attention to the plausibility of skeletal shape, texture, and the state of decay of the corpse to make it look like the skeleton of a real therianthrope.


By deliberately breaking the complete skeleton into pieces and putting them back together, we achieved cracks and other realistic expressions.
Biotic details like teeth protruding from the tip of the toes and fingers were also created from scratch.

Specifications

Size
230cm

Materials
resin, polystyrene foam, Sunpelca, FRP resin, etc.

Production Cost
approx. 5 million yen

Purpose of Use
web ad

02Animals As Art
“Polar Bear Parent & Cub”

Production Background

When Zeppet’s representative was walking along a street in a foreign city, he saw a stuffed polar bear displayed in a shop window. “Polar Bear Parent & Cub” was conceived from his idea to create “lifelike animals by fully utilizing special modeling techniques” without actually killing them.

Our Passion

At the supervision of animal modeling artist Shinobu Matsumura working for Kaiyodo, Japan’s leading figure manufacturer, Zeppet designed the sleeping polar bear mother and child featuring lifelike skeletal frames and muscles, complete with adorable posture.


To reproduce the authentic texture of the fur, the exterior material was also carefully selected.
Bones, muscles, and fats were made of materials with different hardness to reproduce the authentic touch, while fangs, nails, and teeth are precisely made in smallest details to realize an astonishingly lifelike appearance.

Specifications

Size
285cm (mother) / 100cm (child)

Materials
hair material, silicon, FRP resin, etc.

Production Cost
20 million yen (for initial production only. The cost for subsequent commercial production is 14 million yen)

Purpose of Use
artwork

03Animals As Art
“Clone Wanko”

Production Background

After the “Polar Bear Parent & Cub” was released to the press, we received requests from dog lovers to “reproduce their deceased pet dogs”, which prompted us to make a prototype.

Our Passion

We selected Hana-chan, the representative’s beloved dog, and took photos of her, measured her, and ran analyses of her fur and other elements.


In collaboration with an American hair material studio working for major Hollywood movies, we developed hair materials with different textures, colors, and volumes for different parts of the body.

To reproduce the lively flesh and skin of the dog, we developed an original silicon composition to make a quality skin.
From the nails designed to ensure safety to the unique pupil colors, we exploited all technologies available at present to create the ultimate copy.

Specifications

Size
32cm

Materials
hair material, silicon, FRP resin, etc.

Production Cost
approx. 3-5 million yen
(Price may vary depending on the type of the dog.)

Purpose of Use
artwork

Costume Suits

01Local Mascot
“Kurinia-kun”

Production Background

The linear motor-car project designated Nakatsugawa, Gifu Prefecture, as one of its stops. Nakatsugawa City, nationally famed for chestnut (kuri) sweets, requested us to merge Kuri and Linear to create “Kurinia-kun”.

Our Passion

We proposed three body shapes.
1:1 proportion (babyish proportion with big head)
*This is the cutest proportion but not versatile at events.
1:2 proportion (longer body with better head-body balance)
*The proportion is between cute (1:1) and balance (1:3).
1:3 proportion (longer legs make it easy to walk around)
*The proportion is closest to natural human body shape and most versatile at events.


Three options were made available for the budget and production period suggested by the client. By presenting options, the client can make clearer decisions based on various factors.
After the concept and use purposes were identified, the client selected the “cute” 1:1 proportion.


We designed Kurinia-kun to look like a babyish boy and arranged a logo on his back to make sure what the character stands for.


Various verification tests took place to keep his eye level in line with visitors for possible smartphone shot occasions.
A transparent material is used for the eyes to ensure clear view and easy movements of the wearer.

Specifications

Size
180cm

Materials
urethane, Sunpelca, textiles, acrylic plate, etc.

Production Cost
approx. 1.2 million yen

Purpose of Use
events

02 “Silver Suit” from BRAVESTORM

Production Background

The power suit was produced for the hero of our original theatrical movie, BRAVESTORM.
The design pursues toned proportions and stylish silhouettes unlike existing hero suits.

Our Passion

Because the project was the company’s original, our staff personally designed characters. We used 3D outputs for some parts to realize a perfectly symmetrical shape and extreme details impossible for manual work.


To ensure safety both in normal shooting and wire work situations, we incorporated soft materials with firm appearance and wire clasps in the design.


Materials with different density and details were selected based on their photogenic appearance.
Each part of the suit is carefully shaped to avoid a bulky look and retain the stylish silhouette by keeping each part extremely slim.
©︎albatross japan

Specifications

Size
180cm

Materials
coating urethane, textiles, FRP resin, etc.

Production Cost
approx. 6 million yen (per unit)

Purpose of Use
theatrical film

Digital Modeling

01Helmet & Weapons of “Silver Suit” from BRAVESTORM

Production Background

We produced hero suits and weapons used for the shooting of BRAVESTORM, the movie.
To create symmetrical hero suits and weapons with futuristic and complex actions impossible for existing techniques like clay prototype and other manual works, we introduced Objet500 Connex, a 3D printer by Stratasys (approx. 50 million yen at the time of purchase) ahead of other production studios in Japan.

Our Passion

We scanned the head of the actor wearing the suit, produced the 3D data of a helmet matching his head shape through CG modeling, and printed it out with the 3D printer.
Based on the 3D output, we designed two types of helmets, one pursuing photogenic reality suitable for closeup images, and the other one made of soft materials to ensure safety of the stunt double in action.


For the weapon, we included parts mounted with mobile gimmicks from the 3D data production phase.
The combination of output parts and an embedded servomotor realized a gimmick with an opening and closing hatch through external operation.
©︎albatross japan

Specifications

Size
20cm (helmet; height)
45cm (weapon; gun)

Materials
FRP resin, etc.

Production Cost
approx. 5 million yen

Purpose of Use
theatrical film

02Character Figure for Sale
“Silver Suit Type R2” from BRAVESTORM

Production Background

At the occasion of theatrical release of our original BRAVESTORM, we planned the development and release of relevant products.
Silver Suit Type R2, the human-size main character of the movie, was released as a figure with the highest quality.

Our Passion

The inhouse CG department responsible for the visual production built the data for the figure based on the 3D data used for the movie.


After completing details and the surface, the parts were broken into components in the data and were printed out with the 3D printer.
Special modeling staff who produced the suits in the movie finished the surface of the output parts, made casts of each part, and assembled them with different materials selected for durability throughout a long-term display.


The artists then added base coating and meticulous wears and tears to the erect figure to make it look like the real Silver Suit in a movie scene.
©︎albatross japan

Specifications

Size
approx. 600mm (total height)

Materials
cold cast

Production Cost
125,000 yen (tax included / price for mass production version)

Purpose of Use
painted complete figure

Animatronics & Robots

01Tamanoi Vinegar
“Presentation Robot Type 2: Doctor Tamasu”

Production Background

At the completion of a new headquarter building, Tamanoi Vinegar Corporation, the largest vinegar manufacturer in the Kansai area, requested Zeppet to produce a “theatre where a robot makes a presentation of the company to the visitors”.

Our Passion

The studio proposed the facility plan upon directly interviewing the representative director of Tamanoi Vinegar.
In addition to production works ranging from the draft proposal to the completion of the robot, CG characters, and the main HD movie, we took charge of the production of the MIDI system, an integrated control system of the robot, movie, sound, and lighting effects.


For the design, all motions are built in the upper body, while the motionless lower body is fixed to the ground.
We employed a baking finish used for the coating of cars to attain a quality look.
Pneumatic cylinders are used for the robotic motions to achieve animatronics not found anywhere else in Japan.


*The work is a project supervised by Junya Okabe in the past.

Specifications

Size
190cm

Materials
FRP resin, aluminum, iron, etc.

Production Cost
approx. 30 million yen (for the robot only)

Purpose of Use
corporate display

Mass Production

01Soft Vinyl Figure
“Gomera” from Jumbo Monster GOMERA

Production Background

Jumbo Monster Gomera is the studio’s original character featured as a comic and a companion DVD in Televikun and Korokoro Ichiban!, kids’ magazines from Shogakukan. In response to fans’ written request to “make goods”, we developed a soft vinyl figure.

Our Passion

The body suit design used for filming was deliberately deformed for soft vinyl. The clay model took the characteristic shape and mobility of soft vinyl into account. We paid particular attention to its cuteness, whether standing or seated.


Shaping and coloring processes are designed for mass production, which took place in a toy factory in China.

Specifications

Size
23cm

Materials
soft vinyl

Production Cost
approx. 300,000 yen (prototype production)
1,200 yen (unit price of mass-produced product)

Purpose of Use
toy

02Plushie
“Gomera”&“Yokkora” from Jumbo Monster Gomera

Production Background

Jumbo Monster Gomera is the studio’s original character featured as a comic and a companion DVD in Televikun and Korokoro Ichiban!, kids’ magazines from Shogakukan.
In response to fans’ written request to “make goods”, We developed a plushie as a product.

Our Passion

Upon consultation with a liaison from a plushie toy factory in China, we produced the initial test sample designed for mass production.


Until the approval of the final sample, our designer repeatedly created different samples. We further verified mass production samples sent from the overseas factory, upon which we determined the final price of the mass produced version.

Specifications

Size
approx.220 mm

Materials
Polyester (body)
GPPS (bell) / ABS (eyes)

Production Cost
2,090 yen(tax included / price for mass production version)

Purpose of Use
toy