Project Description

Pacmin Studios was commissioned to develop a 1/1 full-scale mockup of a Pratt & Whitney engine for Flight Works Alabama. The project combined authentic engine components with custom-fabricated elements to create a safe, interactive display for the aviation educational center.

The Challenge

The client needed a full-scale representation of the engine that was detailed enough for training purposes but practical enough to fit within a specific architectural footprint. The display had to be mounted against a flat wall, which required the model to be a “front-half” cutaway rather than a full cylinder. The challenge was to maintain the visual depth and massive scale of a jet engine while ensuring the structure was stable, transportable, and integrated seamlessly with a 2D interior graphic on the wall behind it.

The Plan

Authentic Pratt & Whitney hardware, including the blades, hub, and spinner, would be incorporated into a custom-fabricated shell. To solve the visual challenge of the “empty” space created by the half-shell design, we planned a high-resolution internal vinyl graphic to give the illusion of looking deep into the engine core. The entire display was designed as a turnkey solution, engineered to be shipped to Alabama and installed without requiring any additional technical resources from the center.

The Process

The build began with custom-molding the massive engine shell and building a heavy-duty display stand. Once the shell was finished, our team meticulously assembled the OEM Pratt & Whitney components into the structure and integrated custom lighting to accentuate the blade details. After a full test assembly at our Fullerton facility, the model was disassembled and crated for transport. Two Pacmin Studios technicians traveled to Alabama to oversee the delivery and assembly, ensuring the 1/1 model was perfectly positioned against the center’s interior graphics.

The graphic placed at the rear of the full scale Pratt & Whitney aircraft engine model at Flight Works Alabama

A rendering showcasing the color callouts and scale comparison of the Pratt and Whitney full scale aircraft engine model by Pacmin Studios

Closeup of the mounting hardware used by Pacmin Studios to support the full scale Pratt and Whitney aircraft engine model at Flight Works Alabama

Full scale aircraft model bracket and cone at Pacmin Studios

Large custom mold piece for a full-scale mockup of a Pratt & Whitney aircraft engine at Pacmin Studios

Large custom mold shell for a true-to-size model of a Pratt & Whitney aircraft engine at Pacmin Studios

A full scale aircraft engine mockup piece setting in a mold at Pacmin Studios

Large custom mold shells for a full-scale model of a Pratt & Whitney aircraft engine at Pacmin Studios

A full scale aircraft engine piece setting in a mold at Pacmin Studios

A look at the raw shell of a full-scale Pratt and Whitney aircraft engine display model at Pacmin Studios after the foam mold has been removed

Pacmin Studios breaks away a foam mold to reveal the shell of a full-scale Pratt and Whitney aircraft engine display

Pacmin Studios testing the actual engine hardware fit in the raw unpainted engine shell.

Pacmin Studios raises up the full-scale Pratt & Whitney aircraft engine shell for Flight Works Alabama

Pacmin Studios installs the mount to the back of the full scale Pratt & Whitney aircraft engine model shell

Pacmin Studios assembles the full scale Pratt and Whitney aircraft engine model

The finished full scale Pratt and Whitney aircraft engine model made by Pacmin Studios

A woman interacts with the 1:1 scale model of a Pratt & Whitney aircraft engine before it is shipped to Flight Works Alabama for permanent installation

A forklift operator taking the disassembled full scale Pratt & Whitney aircraft engine model off the delivery truck flatbed

Pacmin Studios and Flight Works Alabama team members work together to install the full scale model of a Pratt & Whitney aircraft engine display

The full scale Pratt & Whitney engine display fully assembled at Flight Works Alabama

A full scale model of a Pratt & Whitney aircraft engine accompanied by an educational graphic at Flight Works Alabama

The Win

The final installation provides a powerful, immersive experience for visitors and students, turning a complex piece of aerospace engineering into an accessible and engaging educational tool. By handling everything from custom fabrication to on-site installation, we delivered a turnkey solution that met the client’s specific spatial constraints and timeline. Today, the model serves as a centerpiece for Flight Works Alabama, inspiring a new generation of aviation professionals.