21 hours ago
In amongst the hustle and bustle of the numerous battle scenes in The Lord of The Rings movie trilogy, you might only see each the chainmail garments worn by Aragorn, Gimili and the hundreds of Orcs on screen for a millisecond, but each shirt contained 80,000 handwoven rings made with an electroplated polypropylene plumbing tube coated in pure silver. This was nicknamed ‘Kayne’s-mail’ by actor Viggo Mortensen — in reference to Kayne Horsham, the film’s creature, armour, and weapons art director.
The slow process to create each garment ready for the cameras, looking authentic, but weighing less than traditional chain mail was a time consuming process. Horsham knew there had to be a better way. Over the next six years Horsham created and patented an injection molding process to mass produce lightweight polycarbonate chainmail — named ‘Kaynemaile’ in honor of Mortensen’s nickname thrown Kayne’s way through LoTR. Although, instead of producing chainmail for movies and fashion, it is used for building—dividing interior spaces and protecting exteriors.