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I am a digital prop modeller and mouldmaker with a background in motorsport engineering. My focus is on the "digital-to-physical" workflow—taking complex concepts and engineering them so they function reliably on set. Having returned to the film industry a year ago following five years specializing in Large Scale Additive Manufacturing (LSAM) and CNC for the F1 and aerospace sectors, I now apply those industrial fabrication and 3D scanning techniques to modern prop making. I enjoy the challenge of bridging the gap between a high-detail digital sculpt and a mechanically sound physical build. I am also comfortable working in SFX and set dec departments.…I am a digital prop modeller and mouldmaker with a background in motorsport engineering. My focus is on the "digital-to-physical" workflow—taking complex concepts and engineering them so they function reliably on set. Having returned to the film industry a year ago following five years specializing in Large Scale Additive Manufacturing (LSAM) and CNC for the F1 and aerospace sectors, I now apply those industrial fabrication and 3D scanning techniques to modern prop making. I enjoy the challenge of bridging the gap between a high-detail digital sculpt and a mechanically sound physical build. I am also comfortable working in SFX and set dec departments.

Adam Sankey

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I am a digital prop modeller and mouldmaker with a background in motorsport engineering. My focus is on the "digital-to-physical" workflow—taking complex concepts and engineering them so they function reliably on set. Having returned to the film industry a year ago following five years specializing in Large Scale Additive Manufacturing (LSAM) and CNC for the F1 and aerospace sectors, I now apply those industrial fabrication and 3D scanning techniques to modern prop making. I enjoy the challenge of bridging the gap between a high-detail digital sculpt and a mechanically sound physical build. I am also comfortable working in SFX and set dec departments.…I am a digital prop modeller and mouldmaker with a background in motorsport engineering. My focus is on the "digital-to-physical" workflow—taking complex concepts and engineering them so they function reliably on set. Having returned to the film industry a year ago following five years specializing in Large Scale Additive Manufacturing (LSAM) and CNC for the F1 and aerospace sectors, I now apply those industrial fabrication and 3D scanning techniques to modern prop making. I enjoy the challenge of bridging the gap between a high-detail digital sculpt and a mechanically sound physical build. I am also comfortable working in SFX and set dec departments.

Available to hire

I am a digital prop modeller and mouldmaker with a background in motorsport engineering. My focus is on the “digital-to-physical” workflow—taking complex concepts and engineering them so they function reliably on set.

Having returned to the film industry a year ago following five years specializing in Large Scale Additive Manufacturing (LSAM) and CNC for the F1 and aerospace sectors, I now apply those industrial fabrication and 3D scanning techniques to modern prop making. I enjoy the challenge of bridging the gap between a high-detail digital sculpt and a mechanically sound physical build. I am also comfortable working in SFX and set dec departments.

Skills

ZBrush

Experience Level

ZBrush

Expert

Work Experience

Head of Set Decoration - Digital Prop Construction at Warner Bros Studios (Dark Train) – HBO series

August 1, 2025 - December 1, 2025

Lead set decoration and digital prop construction for Dark Train; scanned items to produce scaled-down copies; used ZBrush to create moulds and props for 3D printing; collaborated with HOD Rob Seex to deliver on-set functionality and reliability.

Senior Digital Prop Modeler at Warner Bros Studios

January 25, 2025 - August 25, 2025

Senior digital prop modeller working with Set Decoration to create physical props from CAD design; designing hand props from conceptual artwork for the SFX department.

CAD Mould Designer / CNC Programmer / Additive Manufacturing Specialist at Total Machining Solutions (TMS)

January 1, 2019 - January 1, 2025

CAD mould design; CNC offline programming; Additive manufacturing using Fanum VTS hybrid (LSAM) and AI Sync 2.0 slicing software; developed moulds for F1 composite parts using Polycarbonate and PEI plastics printed and scaled per CTE values; trained staff; organized show stands and logistics for NEC and international composites shows; trained to use KUKA robot with CEAD extruder for large-scale 3D printing using Airtech Dahltram materials for composite mould manufacture.

Head of CNC/Mould Making Department at Asylum SFX

August 1, 1994 - December 31, 2020

Led the CNC department for 13+ years; maintained machines; created CAD and programmed toolpaths; designed complex structures; operated 3-, 5-, and 7-axis machines; mould making and casting; managed teams, budgets, and safety; knowledge of chemicals and testing; body casting for high-profile clients.

SFX Technician at Tomb Raider (Film)

January 1, 2000 - Present

Mould making and casting breakaway parts for fight and action scenes; created working and breakaway parts for a robot fight scene that would not endanger the actress.

SFX Technician at The World Is Not Enough (Film)

January 1, 1999 - Present

2nd unit BMW and boat stunt support; moulding and creating parts on the BMW Z8; converted a boat that could drive on land but looked like it was sliding; worked with stunt and pyrotechnic teams during filming.