From Parts to Reality: What Goes Into Building Every Pip-Boy

Clean Pip-Boy Product

When people see the finished Pip-Boy, they see the end result.

A detailed wearable prop.

Working electronics.

A weathered finish.

A piece ready to be displayed, worn or added to a collection.

What they don't see are the hours of work that happen before the final power-on test.

At 3D Printed Gaming Forge, every Pip-Boy is far more than a collection of 3D printed parts. It's the result of careful planning, precise assembly, testing and attention to detail at every stage of the build.

Today, I thought I'd take you behind the scenes and show you what really goes into bringing one of these iconic wearable props to life.

It All Starts with Individual Parts

Before a Pip-Boy can be assembled, every individual component must first be printed.

Each piece is checked as it comes off the printer.

Supports are carefully removed.

Edges are cleaned.

Surfaces are inspected for imperfections.

Even with a well-tuned printer, no two prints are exactly the same. Small adjustments are often needed to ensure every part fits together exactly as intended.

This stage isn't particularly glamorous, but it's one of the most important.

Taking the time to prepare every component properly makes the difference between a good build and a great one.

Assembly Is Where the Project Comes to Life

Once every part has been prepared, the real fun begins.

The assembly process is far more than simply putting pieces together.

Every component is test-fitted before moving on to the next stage.

Small adjustments are made where necessary to achieve the best possible fit.

As more parts come together, the project slowly transforms from a collection of printed components into something that genuinely feels like a finished piece of equipment.

This is always one of my favourite moments in the build.

Seeing something that started as digital files become a physical object never loses its appeal.

Electronics Matter Just as Much as Appearance

One of the features that makes these builds so satisfying is bringing the electronics to life.

Once everything has been installed, the testing begins.

Every function is checked.

Every connection is inspected.

The display is powered on and tested to make sure everything performs exactly as it should before the build moves any further.

I never want a customer to receive something that hasn't been thoroughly tested first.

The final inspection isn't just about making sure it looks good.

It's about making sure it works as expected too.

The Finishing Touches

Once assembly and testing are complete, it's time for the final quality inspection.

Every Pip-Boy is looked over one last time.

Any dust or fingerprints are removed.

Every detail is checked.

Only when I'm completely happy with the finished build is it ready to leave the workshop.

These final few minutes are incredibly important.

Customers place their trust in me to create something special, and I believe that every order should reflect the time, care and craftsmanship that went into making it.

Packing Every Order with Care

Packing an order isn't simply the final task on a checklist.

It's the final stage of the customer experience before the parcel begins its journey.

Every item is carefully protected to help it arrive safely.

The same level of care that goes into building the product continues right through to the packaging.

I always imagine what it will feel like when the customer opens the box for the first time.

That moment should feel exciting.

After all, they've followed the journey, placed their trust in the Forge and waited patiently for their order to arrive.

Opening the parcel should feel like the perfect ending to that story.

Why I Share the Journey

One thing you'll probably notice if you follow 3D Printed Gaming Forge is that I don't only share finished products.

I enjoy sharing the entire process.

The printing.

The assembly.

The painting.

The testing.

Even the occasional print failure.

Why?

Because I believe the journey is just as interesting as the finished result.

Every challenge overcome, every lesson learned and every improvement made helps create a better product.

More importantly, it allows you to see the genuine craftsmanship behind every build.

I don't want the Forge to be somewhere you only visit when you're ready to buy something.

I want it to be somewhere you return to because you're curious about what's happening in the workshop.

There's always another project on the printer.

Always another idea taking shape.

Always another story waiting to be told.

Currently Printing at the Forge

One of the things I love most about running the Forge is that the workshop never stands still. As one project is completed, another is already taking shape.

Here's what's currently keeping the printers and workbench busy:

🕷️ Brick Figure Spider-Man

A brand-new large-scale brick figure is currently in production. Once printed, it'll be assembled and prepared ready to join the growing collection.

🖤 Brick Figure Venom

Another exciting brick figure is also on the way. Watching these larger display pieces come together never gets old, and I can't wait to share the finished result.

🎨 Custom Dead by Daylight-Inspired Stylised Figure

One of the most exciting projects on the bench right now is packaging and preparing a custom stylised figure inspired by the world of Dead by Daylight. Every custom piece is treated with the same care and attention as any other project leaving the Forge, and I can't wait to reveal the finished presentation.

These are only a few of the projects currently moving through the workshop, with plenty more ideas already planned for the weeks ahead.

Come Behind the Workshop Door

If you've enjoyed seeing this Pip-Boy come together, I'd love for you to continue following the journey.

Whether it's wearable gaming props, stylised display figures, cosplay pieces or completely new ideas, there's always something exciting happening behind the workshop doors.

Explore the latest products, browse the current collection and keep an eye on the workshop as new projects are revealed.

Because at 3D Printed Gaming Forge, the next build is always just beginning.