MANDALORIAN BELT

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OVERVIEW

I was tasked by the designer (Shawna Trpcic) of the television series “The Mandalorian” to engineer a leather belt that could hug a male and female form to similar aesthetic results. As the belts would need to be put on different stunt actors throughout a given day, they also needed to appear robust while being completely adjustable.

This project required significant R&D on anthropometric data, as well as a keen understanding of 3D modeling, pattern drafting for leather, leather manufacturing, CNC Milling.

ROLE

Anthropometric Interpretation
3D Modeling
Project Management
3D Printing
Drafting
Pattern Making
Leather Crafting
CNC Milling
Injection Molding
Laser Cutting
Sewing

 DRAFTING AND PLANNING

Often a combination of software and traditional drafting are required for a project to run most smoothly.

This project required the use of several planning phase skills:

  • Drafting: To outsource the cutting of 6061 Aluminum with a waterjet process.

  • 3D Modeling: To 3D print prototypes and format tooling for a injection molding.

  • Pattern Drafting: Using CAD pattern drafting software to create patterns for stack cutting with lasers.

R&D

This process can be highly adaptable and versatile, informing decision-making across various aspects of a project. By understanding how each component interconnects, I can make informed choices that optimize the overall outcome.

My expertise in the prototyping process allowed for rapid functional testing without waiting for samples to ship from vendors. The processes that were ultimately chosen to move forward with were:

  • CNC Milling

  • Injection Molding

  • Leatherworking

MANUFACTURING

The production of the final product involved working with four vendors, which I coordinated and mediated for the client and agency.

ASSEMBLY & QC

The project demanded unique, individual belts, requiring careful selection of leather hides and injection mold colors. This creative process allowed for innovation at every step.

WEARABILITY

These belts were just one part of the many items my team made for the "Mandalorian" project. My team created over 50 different full sets of clothing items and armor. Each episode of the Mandalorian had a budget of around $15M.

RESULTS AND TAKEAWAYS

This belt was only a single component of the entire Mandalorian suit and armor. What this meant for the project was the need for nonstop communication between multiple departments: Cut and sew, mold and cast, 3D modelers and printers, etc.

  • R&D is an evolving process: At any time, a nondescript component of a project can force a project to pivot entirely. Covid caused a shortage of urethane rubber mid way through the manufacturing phase of the project. Once the manufacturer was able to resupply, every ounce of the supply was corrupted by a heatwave. The lesson learned is that it is always worth the time to re-test a resupply of product before trusting it in production.

  • Project definitions and boundaries: It is exceedingly important to assign ownership of every component of a project, especially if a given job title could cause assumptions. For example, according to IATSE contractual language, a “belt” is considered a “prop”. This was easily resolved with excellent communication and facilitation.