Making a Custom Iron Throne Chair
How we Made a Custom Faux Iron and Concrete Throne, Cape, Crown, and Scepter for Bosch Tools
Table of Contents
Bosch Tools and Concrete-themed Iron Throne Chair
In collaboration with and commissioned by Bosch Power Tools, WhiteClouds undertook a unique project for the 2024 World of Concrete expo: crafting a custom faux concrete and iron throne chair, crown, cape and scepter in a “Game of Thrones Iron Throne” style. This impressive piece, meticulously designed and constructed by WhiteClouds, seamlessly blends artistry and utility with cutting-edge fabrication techniques to embody the essence of strength and innovation synonymous with the Bosch brand.
Utilizing a combination of 73 3D printed components, 2 lb. EPS foam, and 229 detailed molded resin parts, our team carefully pieced together each element to ensure both structural integrity and visual authenticity. Each material was carefully selected for its ability to withstand the rigors of display while maintaining the desired aesthetic qualities.
To achieve the striking appearance of iron and concrete, the throne underwent a transformative process. A durable polyurea finish was expertly applied, providing both protection and texture to the surface. Then, employing advanced painting techniques, layers of pigment were applied to evoke the rugged elegance of weathered concrete and the timeless allure of wrought iron.
Through the seamless integration of modern fabrication technologies and traditional craftsmanship, this throne stands not only as a captivating centerpiece but as a testament to the boundless possibilities of creative collaboration. At the World of Concrete Expo 2024, attendees weren’t mere spectators; they were integral participants in power tool challenges where champions were crowned and adorned with the distinguished Bosch-branded hand-sewn cape, themed 3D-printed crown and scepter. This interactive engagement not only created unforgettable experiences but also ignited a flurry of social media activity, with numerous photos capturing and sharing the excitement, thereby amplifying the Bosch brand presence across digital platforms.
Designing the Iron Throne Chair
Bosch initially reached out to us with a unique proposition: to craft a concrete throne inspired by the iconic Iron Throne from the acclaimed Game of Thrones series, incorporating power tools and accessories from Bosch’s product line. Embracing this vision, our WhiteClouds designer started 3D modeling various design possibilities prior to commencing any physical construction. Throughout the process, you’ll see significant evolution from the initial concepts to the ultimate designs. With each iteration, Bosch provided invaluable insights, offered suggestions and feedback, and together, we refined the concepts until the final digital designs earned approval through close scrutiny of the 3D renderings.
Early concepts
Final Designs
Building the Iron Throne Chair
The throne was primarily crafted from EPS foam using CNC (Computer Numerical Control) machining, which precisely directs cutting tools along multiple axes to shape materials based on digital designs. EPS foam, known for its lightweight and robust properties, provided ample support for the seated body. While the general form underwent hand sculpting techniques, intricate details such as the arm rests, back designs, and the top structure were 3D printed to achieve fine detail and structural integrity.
To accommodate the size limitations of the printer beds, the creation process involved digitally partitioning the sculpture into smaller, manageable components, each 3D printed with ultra-fine layers of plastic. Assembly of the throne entailed bonding together and smoothing out 66 separate parts with precision and care.
To fashion the ‘iron’ components adorning the throne, we commenced by digitally designing and subsequently 3D printing the assorted drill parts. Utilizing 5 distinct types of drill bits in the design, we then fabricated a mold from the 3D prints, casting 219 individual pieces in colored pewter resin. In the culmination of assembly, these crafted components were inserted into the pre-built holes within the main structure of the throne.
The scepter head was likewise 3D-printed from our digital design, composed of 7 distinct pieces which were subsequently affixed together with adhesive and expertly smoothed. The staff was crafted from a resin casting of an elongated drill bit. At the summit of the scepter, a ‘gem’ fashioned from transparent green resin lent a regal touch to its appearance.
Following that, two crowns were 3D-printed according to the digital designs and affixed to a hard hat suspension mechanism, enabling them to accommodate a range of head sizes. To complete the crowns, 5 resin-casted drill bits were attached to the apex.
Lastly, the cape was hand-sewn, with the embroidered Bosch logo securely affixed to the back.
Painting the Iron Throne Chair
In order to withstand the harsh treatments in transporting a large model around the country from event to event, and to make the surface structurally sound, we hard-coated the entire throne piece, crowns and scepter head in Polyurea ULXT66. We use this hardcoat for most of our large projects, especially outdoor applications and for most of our metal letters and statues. Polyurea is typically applied by ‘spraying’ the finish onto a structure. Among the many benefits are its highly flexible and water-resistant properties, as well as an incredibly quick setting time. Polyurea can be used to protect outdoor or indoor projects that are prone to chemical or physical damage.
Finally, the giant throne is ready for painting. In this case, we opted for a monotone color with light and dark gray that reflects the color and texture of concrete. The resin tools that were attached in the final step of assembly were not painted but the resin itself was colored to resemble pewter metal.
To safeguard the paintwork and the throne itself, a protective clear coat is skillfully administered, offering an added layer of defense against potential wear and tear. This final touch ensures the longevity and resilience of the statue while preserving its exceptional visual appeal.
Social media
We came, we saw, and we conquered concrete! Thanks #WorldofConcrete for the show of the year and for everyone who joined us in-person or virtually!#BoschWOC24 #WOC24 pic.twitter.com/8Hja9EZKRf
— Bosch Power Tools North America (@BoschToolsNA) January 29, 2024
Materials:
- EPS foam
- PLA Filament
- Resin
- Polyurea ULXT66
- Hardhat suspension
Equipment:
- CNC machine
- Foam cutting machine
- Razors
- Sanders
- 3D Printers
- Resin Mold Supplies
- Polyurea Sprayer
- Paint Sprayer
Stats:
- Throne is approximately 46” x 43” x 73.5”and made from 66 3D printed parts and 219 drill bits cast in resin.
- Scepter is 7.7” x 13.3” x 66” made from 7 3D printed parts and the staff is cast in resin.
- Crown is 3D printed with resin cast drill bits approximately 10.9” x 8.5” x 7.5”
Iron Throne Chair Completed Image Gallery
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WhiteClouds is a Next-gen 3D fabrication company. We use 3D technologies to fabricate a wide-range of products for businesses and consumers but our key ingredients are innovation, craftsmanship and creativity. Please contact us to see how we can help with your next project by filling out the form below, emailing us at [email protected] or by calling us at 385-206-8700.