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Special Effects Costume


Robotic Milling & CNC


Concept Design

Founded in 1993, FBFX has become the UK's leading supplier of Special Effects Costume to the film and entertainment industry. We have worked with the worlds leading film directors, designers and agencies.


We offer our clients original and creative solutions utilising our many years of experience and knowledge. FBFX constantly strives to push forward and pioneer ground-breaking techniques, using the latest technologies culminating in exceptional results. Our advanced workshop facilities and 3d-Scanning studio enable us to offer a ‘concept to completion’ service that is second to none.


Services we offer include:

Costume FX, Prop Design/Manufacture, Concept Design, 3d Scanning, 7-Axis Robotic Milling, 3d Printing, Electronic & Mechanical Design/Manufacture.

Our workshops are amongst the best equipped in Europe. Our facilities, combined with the exceptionally skilled team enable us to realise projects to suit a wide range of clients.


SFX Costume has been at the core of FBFX since its inception and is a vital and creative part of our business. Utilising both traditional techniques and state of the art technology, we are able to produce exceptionally high quality assets. From making lightweight armour for opera, film and ballet productions, to spacesuits and helmets for films, to protective stunt costumes, to complex mechanical and electronic devices. Developing pioneering techniques and embracing new technologies has kept us ahead of the competition and we are the company of choice for leading costume designers and directors.


We are proud to be selected to provide a wide range of SFX Costume for recent films including The Martian, Exodus, Guardians of the Galaxy, Wonder Woman and Prometheus 1 and 2.


We have a large scale 7-axis robotic milling system and a dedicated CAD/CAM team. Materials that can be milled include polystyrene, high density foam and plaster. Combined with our Photogrammetry team, accurate mannequins can be produced for costume fitting, and scaling and replication of existing assets can be produced.

Meet the team

Our workshop and scanning facilities are run by leading professionals, covering a wide range of disciplines.

Andrew Dow,


Grant Pearmain,


Jonathan Hancock,

Head of Digital

Jack Rothwell,

3d Scanning Supervisor

Andrew heads up the team focussing on Mechanical and Electronic solutions. He has over 25 years experience leading teams of artists and producing award winning costume for film, TV and theatre. He has worked with the world's leading costume and production designers, consistently delivering an exceptional level of service.

Grant is a classically trained and an experienced sculptor and specialist painter/finisher. He has pioneered the technique for producing light-weight armour with incredible detailing and realism, which is now used in many award winning productions worldwide.

Grant is also responsible for business development and planning.

Jonathan has over 20 years experience in Post Production, specialising in VFX. He has created many award winning idents and commercials for major broadcasters. He holds a licence from the CAA to fly UAV's (drones) for aerial environment and asset capture, providing the client with airborne lidar and photogrammetry systems.

With over 5 years of experience in 3d scanning , Jack is a leading authority in the world of photogrammetry. He specialises in efficient and effective workflow solutions culminating in the ability to capture scans with incredible detail. Clients include Nike, Madame Tussauds and leading advertising agencies, recently winning a D&AD award.

Tom Streatfeild-Moore,

Head of CAD

Project Manager

Alex Dawes,

Head of CNC Milling

Project Manager

Joe Knapper,

Head Leather Worker

Project Manager

Paul Roe,

Workshop Manager

Tom joined in 2008 where his training in Industrial Design quickly established himself as a very capable modelmaker, both in the traditional and digital world. Tom has managed projects ranging from a mechanical heart for the Tinman to the Space Helmets featured in The Martian.


Alex joined FBFX in 2008 and has experience in all aspects of production and manufacture. He currently heads up the 7-Axis Robotic Milling services alongside his other duties as a 3D CAD Modeller and lead PU sprayer. He studied at Loughborough University where he gained a degree in Industrial Design and Technology.

Joe has been with FBFX since early 2009 having graduated in Model Making & SFX at Hatfield University. He very quickly found his niche working in the armour and leather making side of the company, producing costumes ranging from Christian Bale’s cuirass in Exodus to a fully working Exo Suit for Antboy 3.

Paul is a highly experienced metal fabricator and boilermaker, both for large scale projects and more delicate fine art. He has worked on many feature films and theatre productions. Since 2011 Paul has been managing the workshops ensuring the smooth running of multiple projects and ensuring H&S requirements are met.

Working for FBFX

Get in touch

We are always interested to hear from you if your skills match our criteria. We have the following vacancies:

ZBrush Artist (Experienced)

Freelance / FTC


ZBrush Artist - Intern



Please contact us at and include your CV and a covering letter.



We are looking for ZBrush Artists to join our busy team based at Shepperton Studios. We have two vacancies; one for an experienced Artist and another willing to learn from the ground up.


The main aspect of the role is to manipulate scan data produced by our Photogrammetry rigs, including both low and high level clean-up/sculpting, re-topology and texture work. The resulting data will be used by our physical costume makers and/or VFX Artists throughout the industry. There is also the opportunity to be involved in scanning sessions both at our studio and on-set, as well as coordinating/running small projects. Close collaboration with the Scanning Supervisor and other Artists, both digital and traditional is paramount.



• In depth knowledge of ZBrush   (basic level for the Intern position).

• Good knowledge of Mari, WrapX, Maya and KeyShot   (basic level for the Intern position).

• Excellent communication and organisational skills.

• Ability to work autonomously or as part of a team.

• A keen eye for detail.



• Lighting/rendering knowledge.

• Experience with Agisoft Photoscan and/or RealityCapture.

• An interest in film and television production.



You must be able to work in the UK and be within a commutable distance from Shepperton Studios. We mainly work from Monday to Friday but occasional weekend work may be required. No formal education qualifications are required although relevant training and experience is preferable.


Where to find us

Our Workshops are based near Heathrow Airport. The Scanning Studio and 3d Post Production facilities are based at Shepperton Studios.


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Contact details:

To talk to one of our team about your project, or to find out more about what we do, please get in touch using the details below:


+44 (0)208 751 5321

For further details, please get in touch.

Registered Address:

Unit 1 Dockwells Industrial Estate



TW14 0RX