EE: First of all, how many men and women do you typically employ, and what are their specialties?

Dave Merritt: Legacy Effects operates from a core group of about 45 people, and we can quickly ramp up to 150 people as more projects come in. We staff all types of specialists, but we separate them by departments; some departments include more than one specialist. The Departments are broken up into Art, 3D Modeling, Mechanical, Fabrication (which includes hair and fur), Electronics, Molding and Casting, and the Model Shop.

EE: Creativity is an important aspect of Legacy’s production. How often do you start with one design and end up with something completely different based on inputs from different departments?

Dave: We strive to create exactly what our clients desire, but there are times when our staff collaboration may change our approach to the final project. Typically our timeframes are short so a great deal of collaboration needs to happen during the project. For example, we may use materials and processes from one department to replace a more time consuming method in another department.

EE: What percentage of your projects have some sort of motion involved? And do your designers typically use electric, pneumatic, or hydraulic components for the motion?

Dave: About 50 percent of our work involves some sort of motion. That motion can incorporate everything from simple rod puppets to large hydraulic systems depending on the individual project. In Real Steel, the robot Atom was built with rod puppet arms and a hydraulic head which allowed for a smoother and more fluid operation.

EE: For any single project, how many different designers are involved?

Dave: Each department has input on the design of a project. For instance, 5 key designers from various departments were involved with the Iron Man suit. Our Fabrication Dept. dealt with how the materials would work together as a whole; Mechanical worked out hinge points and fasteners, while the Model Shop and Mold Dept. focused on the patterns and casting process.  Then, Electronics followed up with the lighting and wiring harness. Now for something like the aliens in Cowboys and Aliens, the same process applied, but the puppet was more organic, so the Digital and Real World Sculptors, Mechanics and Mold Dept. were more predominate in the build.

EE: How do you use the computers you have in-house, since you don’t provide CGI to your clients?

Dave: We utilize 3D modeling in order to visualize what we are going to build and to identify specific elements that may go through the rapid prototyping process.  We use our in-house system to produce maquettes for clients as well as small detail components.

EE: How many projects do you work on at any one time?

Dave: We typically run four to six television commercials and two to four feature films at one time.

EE: If you had only a few words to explain how it is to work with such a diverse and talented group, what would you say?

Dave: It's a very rewarding experience to be able to work in a creative environment with such talented people.

EE: Thank you for taking the time to answer our questions.

Dave: Thank you.

For more information:

Legacy Effects Home