Back in May of 2022 I was approached by a friend of mine, Veronique, who wanted commission a custom brooch based on the alien ambassador Saru's brooch from Star Trek: Discovery. This project took two years of work figuring out how we wanted to do it and finally realizing the design. So here's a little story about it!
Why We All Love Saru
Image source: https://memory-alpha.fandom.com/wiki/Saru
Ambassador Saru, the first Kelpien to join Starfleet, made a huge impact during the mid-23rd century! Serving on both the USS Shenzhou and the USS Discovery, he not only navigated through the intense Federation-Klingon War but also took command of the Discovery when needed. After uncovering that Captain Lorca was actually his mirror universe counterpart, Saru stepped up as acting captain and led the Discovery to a historic truce with the Klingons, earning him the prestigious Starfleet Medal of Honour. Talk about making waves in the galaxy!
Who Is Actor Doug Jones?
Image source: https://www.imdb.com/name/nm0427964/
Doug Jones is a true chameleon of the acting world, known for his incredible ability to bring fantastical characters to life! Best known for his role as Commander Saru in *Star Trek: Discovery*, which first hit screens on September 24, 2017, Jones captivated fans as the unique Kelpian with his blend of depth and otherworldly charm. That same year, he wowed audiences again with his performance as the Amphibian Man in the Academy Award-winning *The Shape of Water*, reuniting with Guillermo del Toro for a romantic lead role that showcased his versatility. And let’s not forget his return as the beloved Billy Butcherson in *Hocus Pocus 2*—proving that his spooky appeal is timeless. With a career celebrated in songs like Aurelio Voltaire’s "The Devil and Mr. Jones," Doug Jones continues to enchant us with his extraordinary talent and unforgettable roles!
The Making Of The Saru Brooch
Veronique wanted this brooch to be made in silver, however the problem is that that she has very acidic skin, which causes silver to blacken. So we opted to make the brooch in anti-tarnished silver. She provided us with reference images to use to design the brooch for her, as she wanted to have it made almost exactly from the show so she could wear it as a cosplay brooch in her Saru cosplay.
Creating the 3D Model
Using the reference images provided, Mark, who works in my shop, created a 3D model of the brooch, carefully scaling it to look as realistic as possible. Once the design was finalized to match her exact vision, Mark 3D-printed it in resin to create a mold for the pieces. The brooch was designed in three separate parts: the centrepiece, the left arm, and the right arm. At the same time, he also 3D-printed the gem inserts for the centre, allowing us to mold and cast resin pieces that resemble crystal gems for the brooch’s centrepiece.
Printing and Preparing the Pieces
You can see from the images what the pieces look like right after printing them in the resin printer.
Once the resin was cleaned and sanded to perfection, I had liquid rubber molds made to safely produce wax copies for casting in anti-tarnish silver.
After casting, we created a custom jig to securely solder the brooch pieces together, ensuring they aligned perfectly without the risk of breaking.
We even hand-cut and shaped the pins from brass rods, soldering them into place with care for the final touch.
Assembling the Brooch
Here you can see the brooch assembled unfinished and unsigned. Doesn't look like much now does it?
That's where the resin cast gems that go into the brooch bring out the personality of the brooch itself.
One important thing to note: we couldn’t set the gems in place permanently. Why? Because after the piece was signed, we’d need to remove the gems. So, the centre gems of the brooch were temporarily glued in using water-soluble wood glue, allowing us to safely remove them later and set them properly afterward.
Presenting and Personalizing
After the brooch was nearly complete, Veronique brought it to Niagara Falls Comic Con to present it to Doug Jones in person. She even captured a video of him signing the back and checking it out. Judging by his reaction, I’d say he was pretty impressed!
After the brooch was autographed, I took it to George Engraving to have it personalized.
George’s son, Leo, now runs the business and continues his father’s legacy of old-fashioned hand engraving. Leo meticulously engraved Doug Jones’s name and his signature Saru on the back of the brooch. Doug had signed it with a Sharpie, and Leo made sure the autograph became a permanent part of the brooch through his expert craftsmanship.
Final Touches
Once the engraving was complete, we recast the resin, finished the details, and assembled the centre gems in the brooch. I’m thrilled with how it turned out—it’s absolutely stunning! I hope you think so too!
Thanks for reading,
