Pre-Production

Concept & Scripting:

The FracTuff project was built around one core idea: showcase a product that’s engineered to perform in the harshest conditions—whether that’s defense, energy, or heavy industry. From the jump, the concept phase zeroed in on crafting a narrative that put FracTuff’s extreme toughness and versatility front and center. Cinematic visual storytelling helped reinforce FracTuff’s innovative position in the market. Early in pre-production, the client supplied extensive technical documentation, including product reference photos and detailed erosion and cavitation testing data. These materials became a foundation for accurate visual reference and storytelling that demonstrated FracTuff’s ability to withstand extreme conditions.

During scripting, we made sure the voiceover reflected what mattered most: durability, high-performance, and relevance across sectors. The script was written to flow with the visual narrative, guiding viewers through intense, high-stakes environments where FracTuff shines. Early concept frames were developed to present FracTuff products in industrial and defense scenarios. These styleframes set the tone—dark, high-contrast visuals with crisp lighting that highlighted material properties. 

Rapid Prototyping (RP):

We skipped traditional storyboards in favor of a detailed Rapid Prototype (RP). This approach let us visualize animation flow and sequence pacing early. The RP included rough 3D geometry, basic materials, and a scratch voiceover, providing a clear, scene-by-scene structure. We imported STEP files of FracTuff components directly from SolidWorks, then optimized them in Cinema 4D through polygon reduction and topology cleanup.

The RP covered several key sequences:

• It opened with a cinematic flyover of a fracking operation, built out with high-detail 3D assets—manifolds, frack tanks, wellheads, trucks, vehicles, and command centers. Cinematic camera movements guided viewers through the environment, with placeholder UI overlays indicating equipment data.

• The next scene was the FracTuff logo animation. Metallic letters were coated with FracTuff’s signature black primer, then a blue protective layer, transitioning seamlessly to the fluid end component.

• Following this, external and cross-sectional views of the fluid end component demonstrated FracTuff’s coating in action. Internal elements were animated to show application processes, with procedural shaders illustrating each coating layer. Fly-throughs spotlighted internal structures.

• Another RP sequence took things down to the molecular level. We visualized sand particles impacting the FracTuff surface, showing how the coating absorbed and dispersed energy. Simplified simulations, dynamic lighting, and particle effects helped communicate these interactions clearly.

• A heat map sequence highlighted areas of maximum pressure inside the fluid end during operation. Rough molecular grid simulations demonstrated FracTuff’s resistance to particle erosion.

• One of the more complex RP sequences featured a Black Hawk helicopter landing in a desert. We blocked out rotor animations and cinematic camera transitions—from wide shots to tight close-ups on the rotor blades, where sand particles impacted the FracTuff-coated surfaces.

• Additional sequences showed the FracTuff coating application process. We started with a worn fluid end, then animated cleaning, prepping, and coating in stages. Procedural shaders and dynamic lighting emphasized the transformation at both macro and micro scales.

• The RP closed with sequences combining client testing documentation, graphs, and photos. We built infographic animations and placeholders to polish further in post.

Client feedback during the RP review pushed us to dive deeper into defense-related visuals and molecular simulations. Internally, we fine-tuned camera transitions, pacing, and visual flow for stronger continuity.

Production

Look Development:

With RP locked, we moved into full production—finalizing materials, lighting, and animation details. Redshift was key here, helping us develop custom shaders that replicated everything from brushed metals to the complex FracTuff coatings. Subsurface scattering and translucency were dialed in to simulate micro-surface details and authentic light behavior, especially in molecular and particle-driven scenes.

The fracking operation scene was fleshed out with high-detail assets—frac pads, equipment, and vehicles. We introduced a semi-holographic aesthetic with transparent glass shaders, white outlines, and color-coded highlights. Custom shaders reinforced the futuristic UI style, with additional UI elements added in post.

FracTuff Logo and Coating Animation:

The FracTuff logo animation showed raw metallic letters gradually coated with the black primer and blue protective layers. Realistic lighting effects and reflections were integrated, leading seamlessly into the fluid end coating sequences.

Fluid End and Coating Process:

We showed the fluid end component externally and in cross-section, with camera fly-throughs exploring its architecture and highlighting FracTuff’s protective coatings. Procedural noise masks and displacement maps illustrated the application process. Shaders replicated real-life textures based on client reference photos.

We animated the entire coating process—from cleaning and sandblasting the worn component to applying FracTuff’s primer and protective layers. Procedural shaders and animated noise masks conveyed each step. Dynamic lighting highlighted texture transitions and surface detail.

Molecular Impact Simulations:

These sequences were among the most technically complex. Rigid body dynamics simulated sand particle collisions with the coated surface, while subtle deformations visualized energy absorption. Sand particles featured subsurface scattering, translucency, and displacement to capture realistic light behavior. Lighting rigs emphasized the translucent edges and imperfections of individual particles.

A microscopic zoom revealed FracTuff’s siloxane molecular grid. Arrays of spheres formed the lattice, demonstrating flexibility under impact without compromising strength. Lighting and shading balanced clarity and realism at this extreme scale.

Defense Sector Visualization - Black Hawk Helicopter:

The Black Hawk landing sequence showcased rigged rotors and PBR-textured surfaces. We simulated realistic dust and debris effects stirred by rotor wash, using particle systems for sand and dust. Projection mapping handled the desert environment, maintaining photorealism without adding geometry overhead. The camera moved from wide landing shots to close-ups of rotor blades where sand particles bounced off FracTuff’s coating, reinforcing its protective properties.

Scientific Data and Visualization:

For data-driven scenes, we developed MoGraph 3D globes made of cylinders and holographic bar charts presenting FracTuff’s performance metrics. An Element 3D siloxane molecule model, complete with plexus connections and rotating animations, reinforced the scientific focus.

Post-Production

Compositing and Color Grading:

Post in After Effects unified rendered passes—diffuse, reflection, specular, and ambient occlusion—with final color grading. LUTs and color treatments stuck to brand guidelines: dark blues, green highlights, and clean white text.

We added atmospheric effects—dust, haze, and light rays—for exterior realism, especially in the helicopter scenes. Depth of field and motion blur were applied to enhance focus and realism.

Microscopic scenes featured UI overlays showing magnification levels, molecule labels, and data metrics. Subtle particles and glows emphasized the molecular scale.

Data Graphics and Infographics:

We animated tables, graphs, and scientific photos to align with the voiceover. Infographic overlays presented test results clearly. In cavitation testing sequences, we replaced static RP images with animated CFD velocity contours and graphical indicators.

UI and Holographic Elements:

Throughout the project, we integrated 2D UI elements—icons, labels, graphs—into scenes. We kept the holographic design language consistent with subtle glows and motion.

Final Enhancements and Effects:

Lens flares, chromatic aberration, grain overlays, and glow passes were used to heighten realism and guide viewer attention. HUD graphics were composited into microscopic views to reinforce the scientific narrative.

Transcript:

The average fracking operation today involves nearly 240% more hydraulic horsepower than it did in 2012. The result? Oilfield equipment lifespans have been slashed.  Many companies have tried to address this problem by making their materials harder, with little to show for it. 

By reformulating military-grade technology developed by NASA researchers Formula No. 37 has cracked the code and is poised to revolutionize the world of fracking.

FracTuff is a patented coating system that when applied to high-pressure internals of fracking components, it can extend their lifespans by up to 5 times. Improving your ESG and safety And increasing, equipment savings, uptime and overall profitability 

As Formula No. 37 has discovered, the key to preventing corrosion and cavitation of fracking equipment is not harder steel, but protected steel.

FracTuff is a 2-part coating system similar to an elastomer that consists of the FracTuff Prime base coat that mechanically adheres to the substrate, and FracTuff Protect, a nano-composite, siloxane-based top coat that forms a chemical reaction with the base coat.

The coating works by absorbing and dissipating the energy of high-pressure water, acid and fracking sand as it reaches the fluid end, valve, goat head, flow iron, or other metal components that are prone to rapid erosion and corrosion during fracking operations. 

Fluid ends in particular are notorious for failure via fatigue cracking of the intersecting bore, and packing bore washouts. Protecting them with FracTuff ensures they will last two or three times longer, or more with a robust maintenance program.

Manufactured in Houston, FracTuff Prime and FracTuff Protect are a Patented and Proprietary blend of 13 different raw materials and have even been durability tested in space. 

Before a part is coated, we begin by inspecting it for damage or surface irregularities that must be removed before treatment.

Next, the part is thoroughly cleaned to remove all contaminants, and areas to remain uncoated are masked.

The part is then white metal blasted with aluminum oxide abrasive media.

Next, the part is primed by spraying with a base coat of FracTuff Prime.. 

After FracTuff Prime is fully cured, the top coat layer of FracTuff Protect is applied in several layers with specialized spray equipment that atomizes the product.  When the application of the FracTuff Protect is complete, it is allowed to cure in an ambient state.

After fully curing, it undergoes a final inspection and is then ready to be placed in service.

FracTuff is easily inspected and able to be patched in the field with minimal equipment downtime, or stripped and reapplied in a shop environment.

The siloxane matrix is UV and oxidation-resistant, hydrophobic, non-toxic, and chemically inert, with antifoulant properties, performs well across a wide range of temperatures, and has high vapor permeability.   

Although FracTuff is designed for oilfield operations, the formulation is suitable for a wide variety of applications and environments. It was created as the answer to the problem of desert climates destroying U.S. military helicopter blades in Iraq and Afghanistan in the early 2000s.  

The leading edge, in particular, was prone to wear from dust, sand, rain, and other elements impacting the blade at high speeds, necessitating frequent, costly replacements.

In 2002, NASA researchers were tasked by the Department of Defense to develop a fix. The coating system they invented was the basis for the formulation that is now known as FracTuff.

Specially reformulated for the oil and gas industry, FracTuff has proven in test after test that the same technology that can protect helicopter blades is capable of protecting valuable equipment for your company. 

In accelerated erosion laboratory tests conducted by the widely respected firm Stress Engineering, a nominal fourteen-thousandths of an inch coating of FracTuff was shown to improve durability up to 11.8 times for stainless steel commonly used in fluid ends, up to 17 times for alloy steel commonly used for goat heads, and up to 17.2 times for alloy steel commonly used for frac iron.

In fact, Stress Engineering was so impressed by FracTuff’s performance that the company requested to have its own test equipment coated with FracTuff.

In side-by-side comparisons of cavitation tests, it’s easy to note the difference between the performance of popular material coatings such as carbon composite and aluminum, and FracTuff coating. 

The evidence is clear: FracTuff is the patented technology the oil and gas industry has been waiting for. No other product comes close to its ability to fight erosion and corrosion, reduce downtime by prolonging the life of equipment, and increasing profitability by reducing maintenance and replacement cost. 

FracTuff.