Ever wondered how larger-than-life summertime icons come to life? At 360CSG, we’re all about turning imaginative ideas into tangible, interactive experiences. For the Walmart – SpringGrillin event, we took the art of custom fabrication to the next level, creating colossal summer staples like towering ketchup and mustard bottles, a gigantic cheeseburger, and an enormous hot dog. Let’s dive into the behind-the-scenes magic that made this unforgettable grilling season come to life!

Foam Cutting:

To bring these oversized icons to life, we turned to our trusty 5-axis foam wire-cutting machine, affectionately nicknamed Walter (don’t ask). Walter slices through foam with precision, creating the basic shapes for our creations. After the initial cuts, we fine-tuned the details on our flatbed router, ensuring every curve and edge was just right.

Smooth-On:

Durability meets aesthetics with @smooth-on coatings. We meticulously covered our foam pieces with Smooth-On products, providing a strong, glossy finish. This process involved several rounds of spraying, sanding, and repainting to achieve a surface that could withstand the rigors of customer interactions while looking sleek and polished.

Painting:

Painting these massive creations was no small feat. We applied multiple coats of paint to ensure vibrant, eye-catching colors. Each layer was carefully sanded and retouched, creating a finish that was not only visually appealing but also durable enough to handle enthusiastic engagement from customers.

  • 360CSG Momentum Walmart SpringGrillin - Finished Cheeseburger, Ketchup and Mustard Bottles, Hotdog, On-Onsite
  • 360CSG Momentum Walmart SpringGrillin - Unfinished cheeseburger, Smooth-on, Sanded, Bottom
  • 360CSG Momentum Walmart SpringGrillin - Unfinished Cheeseburger, Foam, Raw Cut
  • 360CSG Momentum Walmart SpringGrillin - Unfinished Cheeseburger, Hotdog
  • 360CSG Momentum Walmart SpringGrillin - Finished Cheeseburger, Painted
  • 360CSG Momentum Walmart SpringGrillin - Bottle, Translucent 3D Print, Teeny Tiny Test
  • 360CSG Momentum Walmart SpringGrillin - Cheeseburger, Foam, Unfinished
  • 360CSG Momentum Walmart SpringGrillin - Unfinished cheeseburger, Smooth-on, sanded, sesame seeds
  • 360CSG Momentum Walmart SpringGrillin - Unfinished cheeseburger, Smooth-on, sanded
  • 360CSG Momentum Walmart SpringGrillin - Hotdog, Foam
  • 360CSG Momentum Walmart SpringGrillin - Unfinished Ketchup bottle, Smooth-on, Sanded
  • 360CSG Momentum Walmart SpringGrillin - Unfinished Ketchup and Mustard bottles, Smooth-on, Sanded
  • 360CSG Momentum Walmart SpringGrillin - Hotdog, Foam, Smooth-On, Unpainted
  • 360CSG Momentum Walmart SpringGrillin - Hotdog, Cheeseburger, Foam, Unfinished
  • 360CSG Momentum Walmart SpringGrillin - Splash Bottles, Translucent 3D Print
  • 360CSG Momentum Walmart SpringGrillin - Bottles, Translucent 3D Print
  • 360CSG Momentum Walmart SpringGrillin - Unfinished burger, bare foam
  • 360CSG Momentum Walmart SpringGrillin - Bottles, Translucent 3D Print
  • 360CSG Momentum Walmart SpringGrillin - Finished cheeseburger, Smooth-on, Painted
  • 360CSG Momentum Walmart SpringGrillin - Unfinished cheeseburger, Smooth-on
  • 360CSG Momentum Walmart SpringGrillin - Unfinished Ketchup and Mustard bottles, Smooth-on, Sanding
  • 360CSG Momentum Walmart SpringGrillin - Unfinished bottle, Smooth-on
  • 360CSG Momentum Walmart SpringGrillin - Splash Bottles - Translucent 3D Print
  • 360CSG Momentum Walmart SpringGrillin - Setup
  • 360CSG Momentum Walmart SpringGrillin - unfinished burger, foam, close-up
  • 360CSG Momentum Walmart SpringGrillin BTS Picnic Setup
  • 360CSG Momentum Walmart SpringGrillin - Unfinished burger, foam, Smooth-on, close-up
  • 360CSG Momentum Walmart SpringGrillin - Unfinished cheeseburger, Smooth-on, sanded, sesame seeds
  • 360CSG Momentum Walmart SpringGrillin - Finished Ketchup and Mustard bottles, Hotdog, Painted
  • 360CSG Momentum Walmart SpringGrillin - Setup with people

3D Design:

Designing these interactive pieces was a blend of creativity and technology. Inspired by Momentum and brought to life using Blender (FTW), our designs were meticulously planned to make the best use of Walter (our 5-axis foam cutting wire machine) and maximize the use of the foam blocks that they were hewn from. Kind of like Davinci removing the unnecessary marble from around David… but in hot dog form!!

3D Printing:

We made two 4.5′ tall Splash bottles using clear bio-plastic PLA filament. We chose top-quality filament to keep it pure and clear, and printed slowly with thick layers to fuse them well. We used high temperatures to stick the layers better. For maximum clarity, we filled the bottles completely and carefully sanded and polished them until they shined like glass. These steps gave us beautiful, see-through bottles that really caught the customers’ eyes and made the promotional display stand out.