Theo Hornsey
PIPS Host Organisation: Replicate3D

During Theo’s PIPS placement at Replicate3D, an industrial design and manufacturing company based in Southampton, Theo joined the team just six weeks before a major deadline: the creation of a life-sized 1:1 replica of a mammoth skeleton using 3D printing technology. Although the initial scanning had been completed prior to their arrival, he immediately took on responsibility for 3D printing, post-processing, and assembling the skeleton.

Theo’s role also involved fabricating a custom metal framework to support the structure, which included welding and CAD design. Once printed, each component was painted using air spray guns in professional spray booths. They also engineered bespoke metal connectors to join the mammoth parts together.

Following the completion of the mammoth project, Theo contributed to a variety of day-to-day operations at Replicate3D. These included 3D scanning components from boats and cars, and using SolidWorks to reverse-engineer them for reproduction via 3D printing. One particularly memorable task involved recreating a blast pipe for a steam roller, which was later cast in iron for functional use.

This placement provided a fast-paced, hands-on environment where Theo developed a broad range of practical engineering skills. It also highlighted the importance of time management and adaptability when working to meet client deadlines. Although the experience was very different from his usual academic setting, it proved to be both enriching and professionally valuable.

When asked to share an example of an achievement from his PIPS that he could present to a future employer, Theo highlighted his development of advanced practical workshop skills and industrial CAD expertise. Theo said, “These are skills that I’ve always wanted to be able to have and it is remarkable that the products that I’ve helped to create have ended up being showcased in a museum.”