To create the burnt out and broken bodies of arch villain Ultron's robot army, we first CNC milled a pattern robot using a high density foam board. The robot was milled in multiple parts so that eventually we would be able to assemble versions of it in different poses.

The foam robot parts then had additional detail added to them by our model makers and sculptors and given a smooth finish. The finished model pieces were then moulded and cast out using a strong, lightweight rigid foam material.

The painted and art finished robot pieces were finally assembled into various poses to create 12 contorted and badly damaged robot bodies.