The NHL continued their stadium series this February with the L.A. Kings vs. San Jose Sharks at the new Levi’s Stadium in Santa Clara, and in support of our client’s e2k events x entertainment, we fabricated two giant goalie masks through which the players made their entrance onto the ice rink. The masks, roughly 8′ wide by 9′ tall and 12′ deep, were made from eps foam with a fiberglass coating and featured a center split on hinges that allowed the mask to swing open for the players to pass through. The fabrication called on many different skill sets from our talented fabrication team.
The process began by using 123D modeling software to slice the helmet horizontally to create ShopBot ready cut files. Our CNC machine worked for 3 days straight to cut and label each slice, which was then stacked using vertical dowels to pin them in place. Once stacked, any gaps were filled with foam, and the hot knife and sanding tools were brought out to start smoothing the surface. The masks were then coated with a layer of Aqua-Resin and hand-painted. The protective face mask was created using PVC pipe, and an EZ Bender which allowed us to get the uniform curves needed for a realistic face mask.
The process concluded by putting the giants on large casters for easy transportation and loading them onto a flatbed truck, providing the drivers on 880 quite a show en route to the stadium. The masks for the stadium series proved to be one of the more unique projects JMP has tackled in our 20+ years in the business, and we had a blast creating them.
Click here to see them in action.