Alberton 3D printing company creates one of the world’s biggest FIFA trophies

An Alrode South-based 3D printing company has once again demonstrated its ability to turn ambitious ideas into reality after completing a seven-metre replica of the FIFA World Cup trophy.

Big Ideas Printing, known for its large-scale custom 3D printing projects, was commissioned by Way Out Media to manufacture the giant trophy, which is expected to be displayed on a billboard in Centurion.

Founder Oliver Hay said the project came about after the media company approached Big Ideas Printing with an ambitious concept.

“We do work for a company called Way Out Media. We’re kind of their go-to when it comes to bringing these extraordinary ideas to life.

“They asked us how big we could go, and I said, ‘How big do you want to go?’ That’s how we landed on 7m,” he said.

For the Alberton company, the project marks another significant milestone.

“It’s definitely a milestone for us. We love building giant, impossible things, and I think this FIFA trophy definitely falls within that scope,” said Hay.

The trophy is believed to be one of the largest replicas of the FIFA World Cup trophy ever created.

“From what we can tell, it might be the biggest one in the world at the moment. When I did a quick Google search, I found another one that’s 5m tall in either Dubai or Saudi Arabia, so this might be an unofficial world record,” he said.

Although the structure is not an official FIFA trophy, Hay said the team aimed to replicate the original as closely as possible.

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“It’s probably 90% to 95% accurate to the original. Because of the scale and the manufacturing process, there’s a little bit of variance, but it’s as close as we could make it.”

The trophy was built using polyurethane foam and fibreglass, with the team combining modern technology and traditional craftsmanship throughout the process.

“We used 3D printing and computer-aided design (CAD), but we also incorporated hand carving and hand laminating. It’s really a case of the past meeting the future,” Hay explained.

Despite the enormous size of the project, the company completed the trophy in just three weeks.

“You look at something like that and imagine it took forever to make. We literally built it from start to finish in three weeks,” he said.

Working on a structure of that scale came with several challenges.

“The timelines were pretty scary,” Hay admitted.

“The really cold weather made things difficult because materials took longer to cure. Painting was also challenging because of the temperatures, and then there was the height. Getting up there to work safely was definitely one of the biggest challenges.”

To ensure the structure could be safely lifted and installed, the team conducted design simulations before construction.

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“We did simulations within our design software to identify potential problem areas. It also has a hoisting point so it can be lifted by a crane, so we did in-house testing to make sure everything would work.”

Although the FIFA president was unable to attend due to prior commitments, representatives from AB InBev, Way Out Media, and other stakeholders recently visited Big Ideas Printing to view the completed trophy.

“They were absolutely gobsmacked. You could see their jaws almost hit the floor,” Hay said.

For the Alberton company, the project reinforces its reputation for tackling complex, large-scale builds.

“It means we’re ready to tackle the next biggest thing. “If someone wants the next giant statue, FIFA trophy or whatever it is, and they want it 10m or even 20m tall, we’re ready to take on that challenge,” he said.

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