We were commissioned by Simon Pure Marketing to create an oversized Santa hat for Homer Simpson. The hat needed to scale up to fit Homer’s head, so a custom 3D model was produced and 3D printed. Due to the size, our friends at Agile Manufacturing assisted with printing to ensure accuracy and turnaround speed. The print was produced in multiple pieces, which we fused together using a soldering iron and heat staples for strong structural bonding.

The tip of the hat was reinforced internally with rigid expanding foam and metal rods for durability. Once assembled, we applied generous body filler to smooth the surface, followed by extensive sanding. The hat was sprayed using an HVLP gun with matte red and matte white, then finished with a 1K semi-gloss clear coat to match the original statue.

White soft foam was installed inside the hat to ensure a snug and safe fit for Homer. After completion, the display was installed at the Toronto Eaton Centre, where we made the trip to see the activation live in person.

This project combined large-scale fabrication, structural problem solving, and detailed finishing work, and it was incredibly rewarding to see it proudly on display.