
Revolutionizing Filmmaking: How Virtual Production with iClone and Unreal Engine Transforms Visual Effects Companies

Ken Locsmandi – Owner/Founder of Filmworks/FX, Inc.
Founded in 2001 by Ken Locsmandi, Filmworks/FX, Inc. is a boutique visual effects company with a strong DIY ethos and a determined, underdog spirit. Their team of artists is known for a world-class work ethic, expertly handling diverse tasks while maintaining high standards for quality visual content.
Locsmandi’s career includes work on iconic films like The Matrix, Fight Club, and The Cell. Since its establishment, Filmworks/FX has delivered visual effects for major studios. They contributed to projects such as Geostorm, Gone Girl, Blue Bloods, and House of Cards. Originally, the company combined digital and analog workflows, including a Kodak-certified color film lab. With the rise of digital technology, they transitioned fully to digital VFX in 2007.
As Filmworks/FX evolved, it forged new partnerships and expanded into television production with a facility in New York. There, the team completed nearly 3,000 visual effects shots for major series like Blue Bloods and Hap and Leonard. The company has embraced virtual production to offer greater flexibility and efficiency, adapting to industry trends and client needs.
At the core of Filmworks/FX’s virtual production pipeline are Character Creator and iClone, which integrate seamlessly with Unreal Engine. These tools enable the team to produce high-quality, real-time animations and digital characters with remarkable speed and cost-effectiveness. Character Creator and iClone streamline production. They also elevate creative possibilities. This positions Filmworks/FX at the forefront of innovation in the visual effects industry.
“With Character Creator, iClone, and Unreal Engine, we create stunning visuals. These visuals would have taken us months. We are now doing them in hours sometimes. What would have cost $100,000 is now costing $10,000 or less. You actually get to be more creative. This is because you’re not spending all your time on laborious technical tasks.”
Ken Locsmandi – Director, Producer, Visual Effects Supervisor, Writer

Filmworks/FX, Inc., a boutique visual effects company
I started doing computer graphics in the late 1980s. I used software applications like 3D Studio (DOS), which became Max. I also used Wavefront, the precursor to Maya. At the same time, I concurrently did traditional darkroom film processing. In 1991, I completed my first CG animated commercial. From there I was hooked on the technology.

By 1995 I helped produce a full-length feature shot on 8 mm film. We employed the use of model miniatures and all the effects were achieved in-camera. The use of computers and computer graphics was still costly and cumbersome. However, I knew they would ultimately be the means to create the stories I wanted to tell.
In the late 1990s, the computer VFX industry began to take off. At that time, I ran a small company out of my apartment with home-built PCs. Massive, well-funded VFX companies dominated the industry using expensive SGI computers. Nevertheless, business growth provided opportunities. We were able to do visual effects on films such as The Matrix, Fight Club, and The Cell. Doing films of this caliber out of an apartment on PCs was unheard of at the time.



Leaving what was considered the “garage VFX shop” scenario, I formed Filmworks/FX, inc. in 2001. The name stemmed from Filmworks Laboratory, a cinema processing facility, from which we were renting space. A few years later Filmworks/FX, Inc. purchased Filmworks Laboratory. This was a unique scenario. It was one of the few places in the world. It handled photochemical processing, digital VFX, telecine, film scanning, and digital intermediate (color grading).
Filmworks/FX, Inc. eventually became producing partners on several feature films. They continued to generate VFX work on projects like Apocalypto, Terminal, Knight and Day, Star Trek: Picard, and Blue Bloods. They also contributed to hundreds of additional television episodes and films.
Recently the company has moved into virtual production workflows. We developed a virtual production system that is portable and versatile. We can move the system to any stage and are able to use it outdoors. We employed the system on the film, Flight Risk, directed by Mel Gibson.

Virtual production tools to redefine traditional filmmaking
Characters play an essential role in our work. This includes our in-house projects and service-based client work. iClone, Character Creator, and Unreal have become the core of our virtual production pipeline. The term virtual production will fade away soon, and will just be synonymous with production.
With these tools, Character Creator, iClone, and Unreal Engine, we create stunning visuals. These visuals would have taken us months. We are now able to create them in hours sometimes. What once cost one hundred thousand dollars is now ten thousand or less. You also get to be more creative because you’re not spending all your time on laborious technical tasks.



The Shatner Collection using Character Creator and iClone
The Egard Watch Company asked me to write, produce, and direct a commercial with William Shatner. The commercial featured a watch co-designed by Mr. Shatner.

The commercial would have cost over $120,000 dollars if done traditionally. It would have involved a 10 to 12-hour shooting day. Additionally, a month of post-production and 2 weeks of preparation would be needed. In this case, we did 3 days of “prep”. We shot a two-and-a-half minute interview and the thirty-second spot in 2 hours. Before wrapping, we had a rough edit of the commercial to view. This was remarkable.
“If done traditionally, the commercial would have cost over $120,000 dollars. It would require a 10 to 12-hour shooting day, a month of post, and 2 weeks of preparation. In this case, we did 3 days of “prep”. We shot a two-and-a-half minute interview and the thirty-second spot in 2 hours. Gus, the grey alien, was constructed in about 15 minutes using Character Creator in conjunction with ZBrush. “
Ken Locsmandi – Director, Producer, Visual Effects Supervisor, Writer
The spot involved a full CG warehouse with Shatner’s fictitious space collection. This included such items as The Space Shuttle, lunar rover, satellites, astronaut suits, and of course Gus, the grey alien.
Most VFX artists know how time-consuming it is to build, rig, texture, and animate a character. Gus, the grey alien, was constructed in about 15 minutes using Character Creator in conjunction with ZBrush.


Using a base human model in Character Creator. I simply used the procedural sliders to get Gus’s overall shape. Some minor adjustments couldn’t be done easily in Character Creator. Tasks such as completely smoothing the ears to the skull were done in ZBrush. The GoZ bridge function inside Character Creator enables quick modifications. You can modify the ears in ZBrush and send them back to Character Creator. This process completes in about a minute. The Base model in Character Creator is already rigged. You can modify the model in ZBrush without needing manual re-rigging or binding. The software just does it all behind the scenes. It is phenomenal!


To make Gus’s human skin tone grey, the hue saturation sliders inside Character Creator were used. The other amazing thing about the Character Creator model is that all the facial targets are already made. You can immediately bind mocap or use the iClone AccuLIPS text-to-speech function to the character.
We didn’t have the exact animation placement or dialogue for Gus while shooting. Once we had the final dialogue and staging it took about an hour to adjust it using iClone.
Bronson Beak – reducing costs with the right tools
Bronson Beak is a film project that I wrote many years ago. The project was optioned by three of the major studios in Hollywood. For those who don’t know, an option lets the studio hold onto your project for a minimal fee. They do this until they figure out if and how they want to make it.
This process can take years to iron itself out. In the case of Bronson Beak, it took years for the options to expire till the project rights reverted back to me. The film is an action-adventure comedy. Initially, the plan was to photograph real animals. Then, VFX would place them into the environment and make them speak. We did several tests this way, fairly successfully.





Doing the film this way though would cost about 60 million dollars. My desire was to do the film independently, at a 60 million dollar budget was gonna be a tall order. Any independent filmmaker will contest how hard it is to raise funds.

“Here comes the magic of Reallusion and Unreal. We did tests and it blew my mind. We were able to take CG animals and bound them through ActorCore AccuRIG. Then, we immediately applied motion capture to their bodies and face. Again, my head just exploded when I watched these tests.”
Ken Locsmandi – Director, Producer, Visual Effects Supervisor, Writer
Real-time body and facial capture was being applied to the characters with near real-time rendering. Using our virtual production system I could operate a camera just like filming in the physical world. This allowed us to have instant editorial versions. We just produced a month of work in 45 minutes to an hour. KAPOW! Did I happen to mention my head exploded?



“Because of the Reallusion tool sets and Unreal, we decided to go into production on the project. The company will self-fund initially and then bring on partners. This 60 million dollar film could now be done for less than 1/10th of that original budget, because of these tools. VFX studios not employing these tool sets will not be able to compete in the future. In the right circumstances, iClone and Character Creator will increase your productivity by ten to twenty fold. Time always boils down to dollars.”
Ken Locsmandi – Director, Producer, Visual Effects Supervisor, Writer
To all those filmmakers like me, with no connections or money to make a project, these tools may be just the thing to allow your vision to become a reality. Are there technical skills needed to work these applications? Yes, but they are exponentially easier to use than the industry standard software applications.
My career in filmmaking and VFX has been long. There were eras that were not enjoyable. It became a “grind” to make good stuff. Innovative applications like iClone and Unreal have made this now, the most exciting and fun time.



Follow Filmworks/FX, Inc.
Website:
https://www.filmworksfx.com/
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https://www.linkedin.com/company/filmworks-fx-inc./
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