These actual images were used during the fabrication process to gain client approval.

Colleague Saskia de Zee helped us with the complicated pattern making for the fur. We started making the prototype mechanisms. Colleague Vincent Mensink got he first wing prototypes up and running.

See images of the casting of the head, wings, and the reinforcement in the wings.

Reserve heads, test heads, body, wings. Removing rubber from the head to increase movement.

See images of the casting of the head, wings, and the reinforcement in the wings.

The rubber mould has a core inside to allow the casting of a thin rubber wall. Colleague Padma Koster is seen lining the mould of the body with 6mm of clay to allow for the thickness of fur that will be applied later on in the process.

The mould making materials, silicons and polyurethanes, come from FormX, in Amsterdam. FormX stock the Smooth-On range of casting products. Smooth-On Have been developing their materials so that drying times, pot-life, strength, flexibility are optimised so as to ensure an efficient and easy casting process.

His head has been cut off and cast. It came out in one piece. The feet are cast as well. I'm working on the body...

This is the penguin we are going to cast in rubber.

This is a body without wings. (They get made tomorrow). The body is in a stretched position. This is so that we have enough material in the skin to give freedom of movement later. He will actually sit lower.

The feet are modelled in oil-based clay. The "fingernails" are made from black perspex. Later we will make a mould from this foot and cast it again in coloured silicona rubber.

The head is modelled over a skull with a working jaw mechanism. There is a slight smile on his face. The eyes are slightly humanized.

This is the basic position of the jaw, with the hinge point in the correct place.