Clients - IRT
Model scale – 1:6
Air Stalls- x4
Rivets- x2500
3D printed parts- x400
Magnets used- x112
Moving parts- x72
Horses x12

IRT required 4 exhibition display models of their horse air stalls, used for worldwide thoroughbred race horse transport. These models are to be used as a demonstration and sales tool to explain the services they provide. Therefore all removable and moving parts had to function as they would in reality. This meant adding hinges, magnets and sliding parts. There was a total of 18 moving parts per air stall.

We produced these models with no technical drawings supplied and worked only from images and dimensions provided.
The main structure of the stalls, interior walls and doors consist of laser cut acrylic panels and extrusions. All panel details were etched into the acrylic during the laser cutting stage.
Each individual 1:6 scale brass rivet was drilled and glued in place by hand. There was a total of over 600 rivets per air stall.
The doors and roof panels were hung using brass piano hinges. Each was glued and pinned in place to ensure free movement and strength.

The interior walls and doors are all removable and function as they do on the actual air stalls. They work using a peg and grove system. Groves are situated in both the floor and roof of the boxes. The pegs are located on top and bottom of the walls and doors. This system allows these interior parts to simple slot in out when required. The groves also allow the doors to pivot and therefore function as the full scale air stall.

Interior walls also included sliding partitions. To aid in horse loading and unloading. They help guide the horse into place safely.
We fitted each stall with a scratch proof floor lining to maintain the high quality and prevent the floor being damaged when in use (moving interior parts/taking horses and parts in and out)
The interior wall pads, door stoppers, door handles and large door treads were finished using a rubber coating to best model the texture and look of these parts shown in images supplied to us.

We sunk magnets into the ends of the exterior doors and door openings to hold them closed securely and prevent them flapping open. Magnets were also used in the locking bars to the rear of the model. We located magnets in the back of the interior walls, the inside walls of the air stall itself and in the bars. This allowed the bars to be installed and removed easily just like the real ones. We used 28 magnets per air stall.

The horses supplied with each model were custom painted to the clients request colours. Even the hair colours were made to match. This was carried out by Magpie Model Horses ( They also added the horse rein details to match the clients branding colour.

The final stage of producing these models was adding all the 3D printed details, strap material and vinyl stickers. We modelled and printed each 3D element in house using a DLP (Digital Light Processing) 3D printer which uses UV light curable resin. This type of printer allows us to produce highly detailed parts at small scales. There were just under 100 3D printed parts per air stall.

Bespoke Transport Box and Packaging

We supplied a bespoke transport box, foam crown and inserts with each model to enable IRT to ship these models securely and safely. Two were sent to Australia, one to the USA and one stayed in the UK.
The box itself was constructed from laser cut 9mm MDF panels with box joints holding the corners together. It was then strengthened using 2x1 inch pine battens. One end was glued shut whereas the other could be removed using screws. The inside of the box was lined with foam to hold the base of the model snug. We also built a tray that the model sat on top of to help get the model in and out of the box. The tray also had foam padding and a strap to help pull the model out.

The foam crown was made using a soft foam to prevent damage to the model. The crown slides over the model to create a snug fit between the model and the box itself. It also holds all the doors securely closed during transport and prevent the model rattling around within the box.

We also supplied foam inserts that slotted into the floor and ceiling of the model itself. These make sure the interior doors and walls are held in place securely. Also there was an insert for each horse to stand in. This enabled us to package the horses within the model safely without them rattling around.


The models also came with instructions to make it clear to our clients how the model should be used with regards to the removal and insulation of walls, doors and bars. They also explained how to package the model using the foam crown and foam inserts provided to ensure safe transportation. We took pictures of every detail to clearly explain each step thoroughly.