Case Study: Thingergy achieves rapid large-format 3D printing and completes 14-foot FOX Sports "Cleatus" statue in 10 weeks with 3D Platform

Bringing to life the iconic FOX Sports robot and mascot of the NFL

Thingergy Inc., a North Hollywood studio that builds costumes, props and large-scale displays for film and television, was commissioned by FOX Sports to fabricate a 14-foot-tall statue of the NFL robot “Cleatus” for their lobby. The challenge was to produce a structurally sound, detailed sculpture that houses a 75‑inch screen, sits on a 2,000‑lb stabilized aluminum frame, and meet a tight 10‑week timeline while minimizing assembly complexity.

Thingergy used a mix of seven 3D printers—including the 3DP WorkSeries 200—to print 142 parts, reducing the number of components and post‑assembly labor. The combined print run was 2,681 hours, yet the team completed design, printing, body‑shopping, painting and installation within 10 weeks; the finished statue was transported in a 23‑foot truck to the FOX site. Large-format printing proved faster and more efficient, cutting overall print count and streamlining finishing work.

Thingergy