How CAD CAM Create achieved an exceptional finish for a giant Huel bottle display

Creating a large-scale promotional display that captures attention and reflects brand quality is a challenge, especially under tight deadlines. CAD CAM Create recently delivered a 1.2-metre giant Huel bottle for a trade exhibition in the USA, demonstrating CAD CAM Create’s ability to combine precision engineering with premium finishing techniques. The project highlights how careful design adaptation, advanced manufacturing methods, and innovative finishing processes come together to produce a striking and durable display piece.

The project began with a simple but demanding task: create a full 3D CAD model of the Huel bottle using only the physical product as a reference. Without existing digital files, the team had to reverse-engineer the bottle’s shape and details, ensuring accuracy in every curve and contour.

The main body of the bottle was crafted using a combination of hot wire cutting and CNC routing. Hot wire cutting ensured precise shaping of large foam blocks, creating the basic form quickly and efficiently. CNC routing then added detailed contours and smooth surfaces, ensuring the bottle’s shape was true to the original design.

To guarantee stability, the base included a concealed weight. This hidden feature kept the display steady during transport and exhibition, without detracting from the bottle’s clean appearance.

The bottle’s lid required a different approach due to its intricate grip detail and closure features. 3D printing allowed for precise replication of small details, this ensured the lid looked authentic and complemented the main body perfectly.

The last step before shipping was applying a full vinyl wrap featuring Huel’s branding. This wrap added vibrant colours and logos, making the bottle instantly recognisable and visually striking.

After all components were completed, the bottle was assembled carefully to maintain the integrity of the finish and details. To protect the display during air freight to the USA, a purpose-built shipping crate was manufactured in-house.

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