Custom Fabrication

Precision-built solutions for themed environments and large-scale creative projects.

Recent Work

Virgin Voyages Photo-Op Vehicle

Custom-built for Virgin Voyages as an onboard photo opportunity for the Jack & Rosé experience — engineered for strength and safety, while fully dismantlable for efficient storage at sea.

Large-Scale Stage Prop

Built for transport and rapid setup — this piece fully dismantles and assembles without tools. The apple splits and folds along integrated hinges, breaks down at the center, and detaches from a modular stage that also separates for easy transport.

Interior Signage

Laser-cut acrylic wall signage across multiple interior spaces.

Integrated LEDs

Custom LED integration for props, displays, signage, and themed environments — including embedded lighting, animated effects, custom controllers, and tailored color systems designed specifically for each project.

Custom Themed Bed Build

Fully custom themed bed environment designed and fabricated from scratch with no plans or kit — including the structure, lighting, control panel, and immersive sci‑fi details.

3D Modeling of Environments

Original 3D-modeled and rendered environments created from scratch to plan themed spaces, scenic structures, and fabrication details before physical construction begins.

100W CO₂ Laser Cutter

Industrial 100W CO₂ laser cutter used for precision cutting and fabrication across acrylic, wood, plastics, and custom production work.

3D Print Farm

Part of my in-house print farm featuring 15 FDM printers and 2 resin printers used for rapid prototyping, custom production, and scalable fabrication work.

Custom Mechanical Design & Integration

Designed and engineered from scratch using integrated mechanical systems and modified off‑the‑shelf components including an aluminum turntable, eBike motor, chain drive, and a custom-built tensioning system using linear bearings and guide rods. Demonstrates complete mechanical integration, problem solving, and custom fabrication capabilities.

Multi‑Layer Resin Fabrication

Solid resin blocks fabricated through a 10‑layer epoxy casting process with 12‑hour cure cycles between pours. Each piece was hand sanded and polished with rounded edges for a refined tactile finish, with embedded NFC chips that launch directly to my website when scanned. One version contains aligned floating text across multiple resin layers — a custom technique I developed involving laser engraving into cured resin, adding inlays, and encapsulating them through successive pours.

Precision-driven fabrication across disciplines

I’m a fabricator with over 10 years of experience in 3D design and modeling for 3D printing, laser cutting, CNC routing, construction, and woodworking.

With a strong focus on 3D modeling prior to each build, I develop solutions that resolve design challenges before fabrication begins, ensuring accuracy and efficient execution.

My work combines multiple disciplines into complete builds — from structural fabrication and precision machining to 3D printing, lighting, electronics, and mechanical systems. I utilize a range of materials including wood, acrylic, plastics, resin, and integrated metal components.

Projects range from large-scale installations and wooden props to smaller precision pieces, including commercial installs for Virgin Voyages, large-format builds such as custom vehicles and scenic elements, and high-detail fabrication for themed environments. I have also made props for Walt Disney World (Hollywood Studios) and I have LED Lightsaber mounts on display in the Star Wars Store at Disney Springs.

Most of my laser work is in acrylic and wood, but the same design and file prep translates directly to metal. For metal laser cutting, parts are produced through external processes to spec and integrated into the build.

Every build is executed with a focus on precision, clean fabrication, and a refined final result.

Chris Mansell

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For custom fabrication, themed environments, signage, props, displays, and problem-solving builds.