DAVID CALDWELL

Develop methodologies for producing unique parts specific to the project's final product. Edge was a multidisciplinary special FX company incorporating mechanical and electrical engineering with artists, machinists, and modelmakers working in close collaboration to produce robotic creations that could work both in and out of the water. I developed a way to fabricate molds which were lighter and stronger than traditional style molds. Utilized all sorts of fiberglass fabrics including carbon fiber and polyester, kevlar and sandwich construction in both hand layup, vacuum bagging, infusion and filament winding. Developed the formula for our animal skins out of polyurethane rubber in durometers which worked with our mechanisms and looked realistic. Extensive experience with multiple resin systems: epoxy, vinylester, polyester, polyurethanes both rigid and flexible, polyurea in multiple durometers, and silicone for both mold making and product design. Also conversant with gypsum cement and GFRC for tile and sculpture production. Lead diver on all water production shots.

Feature films: Free Willy 1,2,3, Anaconda, The Secret Life of Walter Mitty, Failure to Launch, The Life Aquatic with Steve Zissou, Austin Powers in Goldmember, Cast Away, The Perfect Storm, Deep Blue Sea, Zeus & Roxanne, Flipper, White Squall, Maverick, The Abyss and Shark Night 3D

Working with Steve Davenport and Dave Casper of Long Marine Lab researched how other museums had prepared their blue whale skeletons for display. Repaired and refurbished the mandibles, maxillaries, nasal and vulmer bones of Ms. Blue.

Using molds from the Cal Academy, San Francisco, fabricated three life-sized elephant seals. They are still being displayed outdoors in front of the Seymour Marine Center, Santa Cruz.

Fabrication Project Manager, with Whale artist, Pieter Folkens, designed how to build a bowhead whale inside the Heritage Center, ordered all materials to be shipped on the annual barge to Barrow, AK, where the team, which now included Steve King, assembled and shaped the foam, covered with fiberglass and epoxy, finished and painted the life-sized whale. It is still displayed hanging inside the center.