Full-scale Heros gladiator figure produced by Monkeyfab for a Stalco trade-show display.

Heros gladiator figure for Stalco

3D scanning, digital sculpting, and large-format 3D printing for a trade-show installation

A physical extension of a branded character

The gladiator figure was created for Stalco as a full-scale exhibition interpretation of the Heros character known from advertising and product packaging. The project combined actor scanning, digital assembly of multiple sources, modeling of missing costume elements, and full exhibition finishing of the final object.

How the figure was built

  • Starting point

    The process started with an actor scanned at the client’s site, partially dressed as the character. He did not have the full costume or props such as the sword, shield, and sandals, so it was clear from the start that the model would require substantial digital development and a combination of several source materials.

  • Building the full character

    The final figure was assembled from multiple scans captured in different configurations — including variants with and without a cape and in several poses. The head was scanned separately with a different device in order to capture a higher level of detail than would be practical in a full-body scan.

  • Digital development

    Missing costume elements were modeled in Blender and ZBrush and then integrated into one cohesive digital character. At this stage proportions, costume relationships, and the overall composition were refined until the model reached the approved version.

  • Production and finishing

    After approval, the model was split into production-ready parts, printed, and assembled into a full-scale figure. It was then hand-finished and painted to achieve the level of detail, texture, and color quality expected from a trade-show centerpiece.

  • Project character

    This was a technically and visually complex project. It required fast body scanning, highly detailed portrait capture, digital reconstruction of missing elements, and a final exhibition-grade finish. The result preserved the recognizability of the branded character while functioning as a compelling large physical object on the client’s stand.

Segments of the Heros gladiator figure after 3D printing, prepared for assembly into a full-scale exhibition object.
Top view of the digital Heros gladiator model during geometry preparation and production planning.
Hand-finishing and painting of the Heros gladiator figure after large-format 3D printing.
Close-up of the digitally refined head scan prepared for faithful facial detail reproduction.
Raw assembled Heros gladiator figure before final painting, showing the scale of the object and the quality of the print assembly.

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