Star Wars 501st Clone Trooper helmet replica created during small business expansion

Small Business Expansion - Ep3: Business focus | Expansion

Small Business Expansion - Ep3: Business focus | Expansion - I wanted to share something a bit different today: the story behind how TheCosforge has grown over the summer, and what that means for you, our customers.

This summer I dedicated time (and a fair bit of sweat) to building out a proper workshop space. I cleared out a corner, got all the tools I needed, sanding, painting, finishing supplies, 3D-printing gear and transformed it into a creative home base. The goal? To take The Cosforge beyond just a few props here and there, and scale up to a full-fledged makers studio where I can bring even more of your favourite worlds to life.

From Hobby to Workshop: Why I Upgraded

When I first started TheCosforge, it was with a handful of props and armor pieces — good quality, but limited by time, space, and resources. As demand grew, I realised: if I want to keep delivering craftsmanship and expand into new fan-favourite universes, I needed a real workspace, a Small Business Expansion.

Now, with the Small Business Expansion, I have the space to: Develop more ambitious, larger-scale props and armor sets, meeting demand. Experiment and refine finishing techniques so each piece comes out crisp and screen/game-accurate. Expand my production run so more people can enjoy pieces inspired by multiple IPs.

Expanding Into New Universes: What’s Next

I’m excited to announce that thanks to the workshop upgrade, TheCosforge will soon launch new lines inspired by beloved franchises like Star Wars, Doom, Halo, World of Warcraft and more. I’ve already begun the prototyping phase, and plan to roll out these new pieces over the next few months.

Expect to see:

3D-printed and hand-painted weapons, armor pieces and accessories inspired by sci-fi and video-game lore. Improved quality and attention to detail. A wider variety of sizes, styles, and collectible-quality builds to suit both casual fans and serious cosplayers.

Why This Matters for You

What this means for you: whether you’re a cosplayer, collector, or just a fan, is that TheCosforge isn’t just a side-project anymore. It’s a fully operational workshop dedicated to crafting high-quality, fan-driven props following the Small Business Expansion.

Because of the improved setup: Lead-times will be shorter and stock more frequent. There will be more variety and more regular drops across different IPs. You’ll get props that hold up better, both in terms of build quality and finish.

Curious What’s Available Right Now?

You can check out the latest catalogue of props, armor and visors over at our shop, I update this regularly, especially with new items planned for release as I finish them.

If you want to stay in the loop for upcoming drops (for example, when the new Star Wars / Halo / Doom-inspired items go live), make sure you’re signed up to my newsletter or following me on social media. I’ll often post teasers and “behind the scenes” glimpses from the workshop before anything is released.

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