Ever wondered how larger-than-life summer icons come to life? At 360CSG, we turn creative ideas into interactive experiences. For the Walmart – SpringGrillin event, we used custom fabrication to make oversized summer favorites. These included giant ketchup and mustard bottles, a massive cheeseburger, and a huge hot dog. Together, they created a fun, unforgettable display that grabbed attention and engaged customers.
Walmart – SpringGrillin
The Walmart SpringGrillin event featured bold, restaurant-inspired food builds. 360CSG transformed everyday favorites into larger-than-life visuals. As a result, customers enjoyed a playful, interactive experience. In addition, these custom pieces reinforced the seasonal theme and boosted in-store engagement. The event left a memorable impression of food, fun, and summer grilling.
Custom Fabrication Process
360CSG followed a clear custom fabrication process for these large-scale builds. First, we shaped and cut foam to precise forms. Then, surface finishing created smooth, durable pieces. After that, painting and detailing brought each piece to life. Finally, every build was made to last while remaining visually striking and interactive for event visitors.
Foam Cutting:
To bring these oversized icons to life, we turned to our trusty 5-axis foam wire-cutting machine, affectionately nicknamed Walter (don’t ask). Walter slices through foam with precision, creating the basic shapes for our creations. After the initial cuts, we fine-tuned the details on our flatbed router, ensuring every curve and edge was just right.
Smooth-On:
Durability meets aesthetics with Smooth-On’s Epsilon Pro coating. We meticulously covered our foam pieces with Epsilon Pro, providing a strong, glossy finish. This part of the custom fabrication process involved several rounds of spraying, sanding, and repainting to achieve a surface that could withstand the rigors of customer interactions while looking sleek and polished.
Painting:
Painting these massive creations was no small feat. We applied multiple coats of paint to ensure vibrant, eye-catching colors. Each layer was carefully sanded and retouched, creating a finish that was not only visually appealing but also durable enough to handle enthusiastic engagement from customers.
3D Design:
Designing these interactive pieces was a blend of creativity and technology. Brought to life by 360CSG using Blender (FTW), our custom fabrication designs were meticulously planned to make the best use of our giant foam cutting wire machine and maximize the use of the foam blocks that they were hewn from. Kind of like Michelangelo removing the unnecessary marble from around David… but in hot dog and burger form!!
3D Printing:
We made two 4.5′ tall Splash bottles using clear bio-plastic PLA filament. We chose top-quality filament to keep it pure and clear, and printed slowly with thick layers to fuse them well. We used high temperatures to stick the layers better. For maximum clarity, we filled the bottles completely and carefully sanded and polished them until they shined like glass. These steps gave us beautiful, see-through bottles that really caught the customers’ eyes and made the promotional display stand out.
Custom Fabrication: Conclusion
In conclusion, the Walmart – SpringGrillin event perfectly showcased the power of custom fabrication. 360CSG turned creative ideas into larger-than-life, interactive experiences that engaged customers and brought summer favorites to life. From foam cutting and 3D design to detailed painting, every step of the process ensured high-quality, durable builds. Ultimately, this project highlights how thoughtful custom fabrication can transform simple concepts into unforgettable brand experiences.
— 360CSG