This week sees the release of the big budget movie premiere, Edge of Tomorrow, starring Tom Cruise and Emily Blunt. The futuristic sci-fi thriller movie has been in the making for the past 3 years.

Alchemie were approached by the lead film/set design company, who were unable to find a suitable material on the open market to meet their challenging requirements. The company required a material suitable for the production of an exo-skeletal combat suit, to be used as the main prop within the film.

Lengthy discussions identified that the suit would be worn by actors for lengthy periods during filming and therefore needed to be of lightweight construction, allow freedom of movement, whilst also maintaining structural stability. The need to have a high impact resistance, high deflection temperature and durability were key factors.

In addition to the complexities required of the material, there were very rigorous time constraints to be met, to ensure the complex suits would be available for the start of filming. This meant that working closely with the customer, through the entire process of development to production, was crucial.

The product is designed for use in low pressure Reaction Injection Moulding (RIM) equipment, and is a neutral, pigmentable system which is formulated to simulate high density polyethylene. The material is ideal for rapid prototyping and limited production runs using, metering machines, with or without vacuum.

Alchemie have been developing both Epoxy and Polyurethane resin formulations for the past 25 years and therefore were ideally placed to take on the demanding challenge. After a complex series of formulations by our research and development chemists, Alchemie succeeded in the development of a two component polyurethane material, which met all criteria. The material will be delivered through a two component (RIM) machine.

Pictured above are the suits worn by Tom Cruise and Emily Blunt.

For more information on how Alchemie can resolve your material requirements please contact us on 01926 641600.