HasLab has sent out a Update #3 email (to those that signed up for it) on the progress of their Exclusive Vintage Collection Jabba's Sail Barge. Below is the entire email with links to videos and images which are worth checking out.

HasLab's Jabba Sail Barge Update #3:

Happy start of autumn, HasLab Insiders! Read on for our latest updates on Jabba’s Sail Barge, including exclusive behind-th-scenes footage of the tool start for our biggest vehicle yet!

Before we could “cut steel” on the first tooled model, we 3D printed a full-scale grey model. Putting the pieces of the 3D model together allowed us to start thinking about box size and pack out (coming soon to an update near you). It also helped us ensure all details were in order before setting sail on the tool start.

We used CAD to plan and design the heavy steel tools that could bring all 250 parts of the Barge to life. In this video, you can see the various parts of the tool being made, from forming the hulking mold bases which sandwich the cavity and core mold parts together to the actual cutting of the mold parts by powerful rotary bits.

Using a method called Electrical discharge Machining (EDM), we also accounted for the smaller details of the barge, where rotary bits are too big to get all of the intricate detail. This was achieved by creating a small copper cast of the desired part, then transferring the design to a steel tool that uses a powerful electrical current to cut the shape into the steel.

Because of the tremendous size of the Khetanna, the steel tools manufactured for this item are some the the biggest we’ve ever created as a toy manufacturer. The process of getting it just right was tireless and passionate effort from our incredibly involved team of talented designers, engineers, and, manufacturing experts.

That’s all for now, but keep on the lookout for our next Haslab Insider report coming later this Fall!

And as always, May the Force be with you!