Prototype 59: Our Halloween 2025 Project

At Protocase, Halloween has become a tradition of creativity and innovation. Every year, we challenge ourselves to create something special for the spooky season, and this year was no different.

A History of Halloween Projects

If you’ve been following us for a while, you know how much we love getting creative for Halloween. Over the years, we’ve tackled some wild projects, from milling an actual pumpkin to manufacturing a custom sheet metal coffin.

Curious to see more? Check out our past Halloween projects here:

• Short recap of all our Halloween creations
• Playlist with videos going through each creation in detail

Raising the Bar in 2025: Prototype 59

This year, we raised the bar with what we’ve dubbed “Prototype 59“. The idea was to create a complex structure from 59 precision-cut sheet metal parts that fit together perfectly.

Thanks to our High Velocity Mass Customization (HVMC) model, we brought this intricate design to life in no time.

The project moved seamlessly from design to our production facility. There, we used our in-house capabilities – including laser cutting, deburring and welding – to transform flat sheets of metal into a stunning final product.

The result? A three-dimensional skull, precisely formed from 59 individual sheet metal parts, with every surface telling a story of detailed engineering and creativity.

“Prototype 59” stands as a testament to our expertise in sheet metal fabrication and our commitment to innovation, bringing complex designs to life. It’s projects like this that showcase the potential of our HVMC model and highlight the skills of our team.

P.S. We also held an internal competition to vote for our favourite scary movie. The winner was The Exorcist, so naturally, we turned it into a custom metal panel.

What should we create next year? After all, it’s never too early to plan! Send your ideas to info@protocase.com and we’ll try our best to make it happen.