The Lab · how he is made
The labclay to vinyl
Sculpted, scanned, printed, cast and painted — eleven parts, nine weeks, one room by the river.
01
Sculpt
Every figure starts as clay on a turntable. Teo sculpts COSMO at twice his final size, so the helmet ring stays crisp when it shrinks.
02
The clay is scanned and split into eleven parts. Each one is printed in resin, sanded and checked against the scan to a tenth of a millimetre.
03
Cast
The prints become steel moulds. Vinyl is spun inside them — rotocast — so the figure is hollow, light and impossible to break by dropping.
04
Paint
Four layers: primer, colour, the cream trim by hand, and a gloss lacquer. Then the number goes under the left boot, and he is ready.