Our latest Spotlight shines on Real SFX, a multi award-winning company that provides an array of special effects including fires, explosions and floods for a range of high-profile projects

We spoke to Real SFX founder Danny Hargreaves about the growth of the business, the importance of local crew and how a certain time-travelling doctor has played a key role in the company’s success…

The early days

I began my career in special effects in 1994 as a trainee on major productions like London’s Burning and Soldier Soldier. It was here that I built my skills, developed a deep passion for the industry, and established my reputation – going on to become one of the youngest BECTU-graded TV supervisors and a full member of the Institute of Explosive Engineers.

In 2009, after relocating to Cardiff to work on Doctor Who, I founded Real SFX. We worked on huge productions in Wales, which was a growth hub for the industry with the BBC studios, and London crew coming down to Cardiff.

Local crew

But that’s all changed now, and we have local crew, not just in Cardiff but across the UK as we’ve expanded. We now have workshops now in Bristol’s The Bottle Yard Studios, as well as in Manchester and Birmingham.

Local crew are a huge part of our ethos and culture, and over the past 15 years I’ve gone from a man with a van to having local Real SFX crew across not just the UK but all over the world.

Our work has earned us multiple BAFTAs and RTS awards, along with a Creative Arts Emmy for Sherlock. One of our proudest moments was undoubtedly working on the Doctor Who 50th Anniversary Special, which was shot in 3D, set a Guinness World Record, and even earned me an invite to Buckingham Palace.

Doctor Who has been a huge part of the Real SFX journey, and we were also part of the 60th anniversary in 2023, which was just as incredible.

I’ve always wanted to push boundaries – whether through innovative SFX techniques or out-of-the-box thinking. Now, we’re creating industry-leading, high-quality effects that constantly drive me to go bigger and better, with safety front and centre.

Fires, explosions and floods, with sustainability at the heart

As one of the UK’s leading SFX companies, we bring a vast range of practical effects to life – you want it, and we’ll make it happen. From pyrotechnics, bullet hits, and gimbal rigs that make a ship rock, to atmospheric effects like wind, rain, and snow. Fires, explosions, floods – you name it, we do it.

Sustainability is also at the heart of our work. We are on albert’s suppliers list, and embed environmentally conscious practices into every aspect of our service where possible – from using biodegradable snow and HVO fuel to e-generators and travel-mapping. Plus of course we have our award-winning initiative KIT4CREW – all to reduce our environmental impact and do what we can to support a sustainable future for our industry.

Blowing up Tommy Shelby’s house…

One of the best examples of one of our high-profile work – and a personal favourite of mine – was the explosive finale of Peaky Blinders, where I had the incredible opportunity to blow up Tommy Shelby’s house. This wasn’t just any explosion; it was a meticulously planned and executed sequence that had to look dramatic and cinematic while ensuring complete safety for the cast and crew (and the actual house!).

From initial concept discussions, to carefully choreographing the detonation, every detail had to be perfect. The explosion had to match the emotional weight of the scene while maintaining the visual style that Peaky Blinders is known for. It was a thrilling challenge that combined precision engineering, pyrotechnics, and creative storytelling, and the final result was spectacular.

And as a bonus, I even got a cheeky cameo in the scene!

On board from the get-go

We are heavily involved right from the start, playing a key role in the conceptual stages of the design process. So we will be involved during pre-production, working closely with the creative team to design and plan the required effects. It’s the same process for both film and TV, though there are always last-minute changes and curveballs, which we are super adaptive to.

Liaising with HoDs

We work closely with the director and various heads of departments (HoDs) to ensure our effects integrate seamlessly into the production. Communication is key, and we’re constantly collaborating with HoDs to fine-tune every detail, which has helped us build strong, long-term working relationships.

We’ll work particularly closely with the art department and producers, ensuring that our effects align with the creative vision while enhancing the storytelling. This collaboration allows us to push creative boundaries while maintaining authenticity and visual impact.

At the same time, we typically liaise with the line producer to ensure that everything stays on track financially.. This close co-ordination ensures we deliver high-quality, innovative effects without compromising production efficiency.

Biggest single feat

Set-ups can vary massively depending on the complexity of the effect, with most requiring weeks or even months of meticulous planning.

One of our biggest recent challenges was building the custom-made rocker for Last Breath in Malta – an epic technical feat that required months of preparation and collaboration across multiple departments. The entire planning phase took place in Wales, starting with initial sketches, CAD designs, and 3D modelling, where we worked closely with the art department to perfect the design.

A crucial part of the process was also collaborating with structural engineers to ensure every safety aspect was meticulously accounted for, while refining the exact sizing, weight, and structural integrity. Engineering and physics played a vital role in every detail. Beyond the design, we also had to navigate the complex logistics of transporting all the materials to Malta and determining the most efficient way to construct it on location.

When everything arrived in Malta, there were riggers and other teams on site, but the core Real SFX team consisted of just five of us! With only four days to construct one of the largest rockers ever built – using 60 tonnes of steel – the pressure was immense.

To add even more pressure, one of the pistons failed just 24 hours before filming was due to start………..luckily I had a spare and managed to pull it off. The final results were incredible, and I was so proud of the team and the effort that went into making it happen.

You can see the exclusive behind-the-scenes footage to see how the team tackled this high-stakes setup under extreme time pressure here.

Time is the biggest challenge

Executing complex effects, keeping up with evolving safety regulations, working within budgets are all potentially tricky – but the biggest challenge is always time. You only get one shot to make an effect perfect, so the pressure is huge.

The industry as a whole has also faced some major challenges in recent years – COVID, the writers’ strike, and the cost-of-living crisis have all put a huge strain on productions. We saw first-hand how crews were struggling on set, which is why we launched KIT4CREW with support from BECTU and CULT Cymru. It’s a sustainability-driven initiative that redistributes workwear across the industry, promoting inclusivity and reducing waste.

Best bits

There have been so many highlights! While we’ve won numerous awards in a short space of time – which is fantastic – that’s never been our priority. It’s all about delivering jaw-dropping SFX and pushing our reputation as the best even further.

We’ve been involved in a number of ground-breaking TV firsts, and one particularly exciting project was the live Coronation Street episode marking its 50th anniversary, featuring the huge tram crash. It pushed boundaries and demanded absolute perfection. While we always aim to get everything done in one take, this was next level.

More recently, we’ve been working abroad on major projects, collaborating with US crews to bring their vision to life. It’s been an incredible experience and a hugely exciting step for our future.

Recent production credits

It’s been a madly busy time for us! Some of the recent projects we’ve had the privilege to work on (the ones we can now talk about as they have been released!) include:

● Last Breath, starring Woody Harrelson and Finn Cole, recently released in the UK
● Netflix’s Havoc, starring Tom Hardy
● These Small Things with Cillian Murphy
● BBC1’s Dope Girls and Lost Boys & Fairies
● Paramount’s The Crow Girl and Sexy Beast
● The latest season of Doctor Who (of course!)
● And we’ve also just finished filming with Guy Ritchie on Young Sherlock

Other credits include Fool Me Once, Black Cake, Luther, His Dark Materials, Disney’s Willow, Expendables 4, Jolt and Free Fire.

Plus many, many more exciting projects we are working on at the moment – watch this space…

With many thanks to Danny Hargreaves and the team at Real SFX for their help in compiling this article.

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