Jabba's Sail Barge Updates

On this page, We will continue to add any of the official HasLab updates on Jabba's Barge. You are also welcome to head over to https://www.hasbrolab.com/#updates to check out more.

HasLab Jabba's Sail Barge Update #4

Star Wars fans,
We're excited to bring you a behind-the-scenes look at packaging development for the barge, including the process of placing the barge in a diorama set that includes over 900(!) pounds of sand - sorry, Anakin.

As we set out to design the packaging, we referenced the original Kenner Ewok Village playset box. However, due to the size of the box and the detail of the model, we decided to eliminate the additional panel of inset illustrations in order to include more photography highlighting various features of the barge.

Below, check out the mood boards for design inspiration for the front panel
Behind The Workbench: Packaging Layout (Pt1)

Back panel
Behind The Workbench: Packaging Layout (Pt2)

and the top & bottom panels
Behind The Workbench: Packaging Layout (Pt3)

To capture all of the photographs we needed for the package, we first needed to steer the barge on its inaugural voyage through the halls of Hasbro, from the model shop to the photo studio. In the time-lapse video below, you can see the barge's journey, as well as the building of the photoshoot set. The set included three different varieties of sand for coloring effect and a specially designed tentacled Sarlacc. Ultimately, we ended up with three different images of the full barge: one with the Sarlacc tentacles, one without the Sarlacc tentacles, and one at less of an angle.
Not to be overlooked, the Sarlacc set piece was a beast in and of itself. As you can see in the image below, each tentacle was molded separately and contained a wire that allowed us to bend them into position.
Behind The Workbench: Packaging Photo Shoot (Pt1)

Of course, Star Wars expert Mark Boudreaux wasn't far from the set during our session. Below you can see him opening the shutters of the barge to get the "full effect".
Behind The Workbench: Packaging Photo Shoot (Pt2)

But what would Jabba's Sail Barge be without Jabba's court of denizens? In the image below, see the lucky characters that made the photoshoot cut.
Behind The Workbench: Packaging Photo Shoot (Pt3)

Like they say in the business, that's a wrap. Check back for our next Haslab Insider update and as always, May the Force be with you!

HasLab Jabba's Sail Barge Update #3

Read on for our latest updates on Jabba's Sail Barge, including exclusive, behind-the-scenes footage on 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!) and make sure that 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 the video and images below, you can view 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.
Behind The Workbench: Tool Design & Construction (Pt1)Behind The Workbench: Tool Design & Construction (Pt2)
Using a method called Electrical Discharge Machining (EDM), pictured below, we also accounted for the smaller details of the barge (where rotary bits are too big to get all of the intricate detail) by creating a small copper cast of the desired part, then transferring that design to a steel tool that uses a powerful electrical current to cut the shape into the steel.
Behind The Workbench: Tool Design & Construction (Pt3)

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

Keep an eye out for our next HasLab update coming later this fall!

And as always, May the Force be with you!
HasLab Jabba's Sail Barge Update #2
Star Wars fans,
In this update, we're taking you behind the scenes to see more of the exciting deco and detailing of the barge.

Below you can see the film references from Star Wars: Return of the Jedi that were used as a basis for creating the interior and exterior details of the ship. To the left of these reference images, you can see the exploded barge model and the different colors and glosses used for each section.
Behind The Workbench: Deco Development (Pt1)

View the mold and paint specifications for the barge and how we've brought some of the smaller details of the ship to life.
Behind The Workbench: Deco Development (Pt2)

Then zoom in and explore the inspiration behind some of the barge's smaller details. With a ship of this size, the opportunity to develop these minute details is vast - and no detail has gone unnoticed.
Behind The Workbench: Deco Development (Pt3)

Making Jabba's sail barge as authentic as possible has been a high priority for us from the start. To meet this promise, we actually printed a 3D, 12-inch model cross-section for our early discussions with Lucasfilm that let us see how the colors would work together. This helped us decide which elements of the barge would be wood versus metal, rusty versus clean, etc.

Check out this video and two visuals out for an inside look at the color and paint choices for the barge.
Behind The Workbench: Mini Deco Model (Pt1)Behind The Workbench: Mini Deco Model (Pt2)
Of course, what would Jabba's sail barge be without its iconic sails? We went through several renditions of the sails before landing on our current design, pictured below, which features soft goods sails and a strong plastic rigging system for ultimate support.
Behind The Workbench: Sail Development

Be on the lookout for the next HasLab Insider Report later this summer, but until then: sail on!

And as always, May the Force be with you!
HasLab Jabba's Sail Barge Update #1
Star Wars fans,
Thank you so much for making the dream of creating Jabba's Sail Barge a reality and joining us on the maiden voyage of HasLab. Without the 8,000+ backers who supported this initiative, this project would not be possible.

As promised, we're keeping you apprised of exciting developments along the road to barge completion, beginning with our first monthly HasLab Update to give you an even deeper look into the development process.

Watch the video below to see the pieces of the barge laid out for our first completed prototype.
Then check out the accessories right out of the print bed and finally, the completed prototype.
Behind The Workbench: Prototype Build (Pt1)Behind The Workbench: NYTF Prototype Build (Pt2)

Also check out the most recent exploded model views from the final CAD models, including cannon and fin sculpt details.
Behind The Workbench: Sculpt Development (Pt1)

Another collaborative idea that we're excited to share with you is the addition of a fan-requested custom rail design that is compatible with existing Vizam cannons (sold separately).
Behind The Workbench: Sculpt Development (Pt2)

To deliver best-in-class Star Wars products to our fans, we depend on a great partnership with Lucasfilm. For example, during development we didn't have the full-photo reference of the wall-mounted rancor detail we wanted to include. It wasn't until later in the process, when Lucasfilm and Disney discovered new photography of the original prop, that we were able to create the authentic representation.
Behind The Workbench: Sculpt Development (Pt3)

This journey to Build the Barge has been about working as a team to create a final product that all of us - from Hasbro to Lucasfilm to fans - can be excited for and extremely proud of. Keep an eye out for future monthly HasLab Updates, and let the countdown to the barge begin!

And as always, May the Force be with you.
Hello Colour and ... Now Including YAK FACE!
After nearly 200 hours, 50 different paint colours and multiple pieces of camera equipment to get the perfect shot, we present to you the fully painted model of Jabba's Sail Barge - The Khetanna. No, this is not an old Jedi mind trick.
Barge 1Barge 2
Barge 3Barge 4
Barge 5Barge 6
Barge 7Barge 8
Barge 9Barge 10
Oh, and SURPRISE FROM JABBA! In addition to Jabba's Sail Barge, The Khetanna, HasLab backers will also receive a 3.75” Yak Face figure from The Vintage Collection, if the campaign is fully backed. (But wait, there's more!) This figure will come in exclusive Power of the Force card back packaging, paying homage to its original release in 1985. And would we be remiss to forget the exclusive Collector Coin? Don't worry - that's in there too.
Yak Face Barge Exclusive
Packing 101
Yes, this dream vehicle is nearly 4 feet long, but what does that mean for packaging? Here's Hasbro's own Mark Boudreaux with the white box mock-up for size.
Sneak Peek at The Vintage Collection: Jabba's Sail Barge (The Khetanna) booklet
Hot off the (digital) press! Here's your sneak peek at just 6 of the 64 pages in the behind-the-scenes booklet that will be included in your purchase (if the minimum number of backers is reached by the deadline). Complete with set photos, product blueprints, interviews, and more, this booklet immerses you into the entire development process and is sure to be a great conversation piece and part of your collection.

And remember, the booklet is only available with the barge; back the project here! It will not be available anywhere else.

View / Download
A closer look at the barge (prototype)
Your response has been incredible and we couldn't be more excited about what's to come. In case you haven't seen them, here are a few of our favorite close-up and detailed photos of the prototype.
Barge ArmoryBarge Armory
Barge CockpitBarge Full
Barge FullBarge Gallery
Barge Gamorrean MuralBarge Lounge
We encourage you to check back here frequently for all the latest updates.