Manchester Arndale Christmas Grotto Stars

Project Overview

Fibre Moulds was commissioned to design, manufacture and deliver a series of large-scale decorative stars for the Christmas Grotto installation at Manchester Arndale.

The project involved the creation of five illuminated stars, each standing approximately four metres tall. Designed as a key feature within the Christmas display, the structures needed to be visually impressive, durable and suitable for repeated seasonal use.

From initial concept through to final manufacture, Fibre Moulds managed the entire process, delivering a solution that remained in service for approximately four years.

The Challenge

Due to their size, each star could not be manufactured as a single component. Instead, every star was engineered as a sectional structure consisting of five individual segments that would be assembled on site.

This created a significant manufacturing challenge.

Each segment had to be produced with exceptional accuracy to ensure all sections aligned perfectly during assembly. Even minor variations could prevent the completed structure from fitting together correctly.

In addition, the installation required materials that complied with fire safety requirements while maintaining strength and durability for long-term public use.

Our Solution

Fibre Moulds managed the project from design development through to final production.

The manufacturing process included:

• Pattern creation

• Mould production

• Component manufacture

• Assembly preparation

• Finishing and quality control

Each star was manufactured using fire-retardant resin to meet the project's safety requirements.

The structures were carefully engineered so that all five sections could be securely bolted together on site while maintaining the appearance of a seamless finished product.

Extensive quality control was carried out throughout production to ensure every segment matched perfectly and could be assembled efficiently during installation.

Manufacture & Delivery

The project was completed over a period of approximately four months.

Key stages included:

• Design development

• Pattern manufacture

• Mould production

• Fibreglass component manufacture

• Fire-retardant finishing

• Assembly testing

• Delivery and installation support

Through careful planning and precision manufacturing, all five stars were successfully produced and assembled as intended.

Outcome

The completed stars became a prominent feature of Manchester Arndale's Christmas Grotto installation, helping to create an engaging festive environment for visitors.

The structures remained in use for approximately four years, demonstrating the durability and quality of the finished product.

This project highlights Fibre Moulds' ability to manage large-scale bespoke fabrication projects, combining technical manufacturing expertise with practical installation solutions and long-term performance.