
Orbital FX: Inside the World of Practical Effects, Prop Building & the Future of Filmmaking
Orbital FX: Inside the World of Practical Effects, Prop Building & the Future of Filmmaking
šļø Episode Overview
In this episode, Steve Otis Gunn sits down with Luke and Paul from Orbital FX, the North-Eastābased practical-effects and prop-building team whose work spans Star Wars, Marvel, Disney theme-parks, and fan-favourite replicas for collectors around the world. They dive deep into the lost artāand unexpected resurgenceāof practical effects: from Ray Harryhausen to The Mandalorian, from clunky 80s prosthetics to cutting-edge CNC and 3D printing. Luke and Paul explain how they build everything from screen-accurate helmets to carbon-fibre Darth Vader pieces, giant convention displays, and even props that end up being purchased by Disney itself for use in productions. Along the way, they share behind-the-scenes stories involving Star Wars fandom, the 501st Legion, building a full-size Millennium Falcon event piece, restoring the original Boba Fett blaster for Adam Savageās Tested, and navigating the strange legal/industry grey-area of replica prop making.
Itās an episode full of nostalgia, technical nerdery, industry insight, and the occasional existential dread about the future of AI, streaming, and the entertainment industry.
Highlights include:
- Why practical effects are making a real comeback
- The surprising ways modern CGI artists depend on physical props
- Prop-building tech: moulding, casting, carbon fibre, CNC, vac-forming, electronics
š About Orbital FX
Orbital FX is a UK-based practical-effects and prop fabrication studio. They specialise in 3D design and printing, mould-making, casting, carbon-fibre builds, CNC machining, vac-forming, silicone work, electronics, leatherwork, soft goods, and full costume fabrication. Their work has appeared at global fan conventions, in Disney Cruise Lineās Avengers: Quantum Encounter, across major Star Wars costuming groups, on Adam Savageās Tested, and in film-adjacent commercial and live-event productions worldwide.
From screen-accurate helmets to large-scale display pieces, Orbital FX blends high-end craftsmanship with genuine fan passion.
š Connect with Orbital
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Podcast: Television Times with Steve Otis Gunn
Host: Steve Otis Gunn
Guests: Luke & Paul from Orbital FX
Duration: 58 minutes
Release Date: December 11, 2025
Season: 4, Episode 30
All music written and performed in this podcast by Steve Otis Gunn
Please buy my book, You Shot My Dog and I Love You, available in all good bookshops and online.
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