One of the biggest challenges with large themed structures isn't manufacturing them—it's figuring out how to create something that can be transported and assembled efficiently without compromising the original design.

For the Odyssey Blackpool project, we were provided with a client-designed concept that needed transforming into a durable, large-scale structure.
Because of the size of the piece, it couldn't be manufactured as a single unit. The design was divided into multiple sections, each carefully produced from shaped polystyrene before being coated and reinforced with fibreglass.
To ensure accurate assembly, each section was manufactured with integrated flanges, allowing the structure to be securely bolted together while maintaining the integrity of the original design.

Our scope of work included producing the sectional components, applying the fibreglass reinforcement, and incorporating the bolted flange system ready for assembly and finishing.

Projects like this are a great example of how successful fabrication relies on planning, engineering and problem-solving just as much as the manufacturing process itself.

It's always rewarding seeing a concept move from design to reality.