Posted on Wednesday, June 25, 2008 on tarheelfilms.com
By: Mike Gunning, Freelance Reporter
The “fascia” of Hollywood set design may be rapidly changing if a Piedmont Triad inventor has anything to say about it.
Weldon Sipe, a retired location manager with several major Hollywood motion pictures to his credit, has developed a new way to erect temporary sets for the stage and film industry, at a fraction of the cost that traditional set constructions takes. Sipe has started Hollyworkz Set Structures LLC, a North Carolina based company, that provides reusable support structures of various architectural shapes that can be arranged, assembled and finished by set construction crews to accommodate whatever the movie script or stage production requires. A prototype was recently unveiled to a select audience: “I was amazed at the simplicity in setting up the frame structure.” Rebecca Clark, Director of North Carolina’s Piedmont Triad Film Commission, said after being the first to view the project. “I was also impressed that the pieces were so lightweight that I could easily pick one up, yet they are strong enough to withstand the elements.”
Sipe, whose youthful appearance and unbridled enthusiasm belies his sixty years, said his product is unique because each structure is assembled using Latch-and-Lock technology. “These structures are assembled without the use of tools or any fasteners such as nails, screws, bolts or welding,” Sipe said. “A crew of only two men can assemble a movie-sized house frame in a matter of two hours. Taking them down is just as easy. This is really going to save the industry a tremendous amount of time and money.” Three quarter inch tongue and groove OSB board is mounted to the frame by sliding the sheets into sheathing tracks of the frame, offering stability to the structure. Once assembled, talented set designers can dress the fascia, or exterior panels of the frames, to meet their needs. The frames themselves are manufactured using all recyclable material, making the use of the product “Green friendly.” Since the structures for movies are for conditional use and are not meant for occupancy, construction codes and time consuming inspections do not apply. Hollyworkz structures are so versatile that panels may be rearranged at will to make different sets on the same spot in a single day. Sipe, who has worked with such Hollywood legends as Steven Spielberg, estimates that sets can be constructed eighty percent faster, at half the cost. “Our basic component of a floor, roof or wall is a latch and lock prefabricated panel, they’re all essentially the same.” Sipe said. “A wall panel can be converted to a roof panel with ease, and dressed as the set designer needs to create the effect he’s trying to achieve.” Sipe said the prefabricated panels also cut down on site preparation. “We use a simple jacking system to level the structure frame,” Sipe said. “That means site preparation, such as leveling or placing a foundation, is no longer necessary.” Sipe said he realized his system could appeal to markets outside the film industry. “Because these frames are so versatile, and can be latched together and taken apart with ease, they can be used to convert open floor space to usable office pods in a matter of minutes.” Sipe said. “They’re very versatile, and built to last if needed once they are properly assembled with permanent fasteners.” The frames could also have humanitarian applications. For temporary use, no fastener system is required, but Sipe said with permanent fasteners on a solid foundation, his frames could be used as a quick resource to offer emergency shelters to those affected by catastrophe, such as Hurricane Katrina. In temperate climates, where insulation is not a concern, the frames could be the start of inexpensive permanent shelters for those in developing countries.
As enthusiastic as Sipe is about his work, he said he was most proud that he found the resources to bring his concept to fruition using local talent and resources. Hollyworkz has formed a business alliance with several industrial partners. These partners have provided all the materials, fabricated pieces, industrial space, and engineering services for the project. In exchange for their participation in the development of the prototype, each will become a permanent supplier of what components they have contributed when production begins. “I am fortunate that I am living in a state where people will still rally around a good idea and lend a helping hand toward a successful outcome.” Sipe said. “I could not have done it without them.” Weldon Sipe's career on Hollywood spans near 20 years. Some of his credits are listed on IMDb.com. He resides in North Carolina where the pre-fab structures are being introduced. Hollyworkz Set Structures are patent pending and Sipe is a candidate for an Academy Award in Engineering Achievement. He can be reached at 336-671-7853.
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