Hi everyone, Earl Hays Press here. We want to address some of the concerns we're seeing on the forum. We share your love of history, creation, and especially exhausting attention to detail. So in the spirit of that last point in particular, we want to address a few aspects of the production process and the choices we made along the way.
The X is made with Amberlith. We haven't found any old rolls of Rubylith at our shop, we've only found the one roll of Amberlith that is seen in the Tested video, so there is no danger that we've accidentally used Rubylith. To ease your minds, the photo below is an old negative used to create a printing plate that uses both Amberlith and Rubylith. Amberlith is used to cover up the name on the certificate while Rubylith tape is used to block out any gaps from the seams.
Even though we can see partly through Amberlith and Rubylith, when photographed by a camera called a stat camera, both materials show up as pure black. This process produces a film negative that is then used for making printing cuts. The one photographed here is a film negative that is being modified (in this case, the name is being removed for a new print - the Amberlith blocks the name from being visible to the stat camera for the new negative). As you can probably guess, this was an exhaustive and time-consuming process to make even the most minor changes. Computers and digital printing drastically revolutionized the graphic design and printing industries, hence Ulano's decision to stop producing Amberlith in 2007.
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Another concern brought up is the photo composite. A user suggested the original photo on Harrison Ford's badge may be the same as a costume continuity photo that is being sold in auction this November. In the continuity photo, Ford is wearing a tan jacket and the light is coming from the right side of the frame. On Ford's ID seen on screen, he is not wearing a tan jacket and the light is coming from the left side of the frame. Moreover, if the continuity photos were taken on instant film (they are the right dimensions to be cut from Polaroids, but it's hard to tell from the low-res image), then there would be no multiples of the same photo. Needless to say we also cannot access the auctioned item for a higher-resolution scan.
We also see that many are concerned about the lamination being trimmed to the edge of the ink. This decision is based on Rick Deckard's badge in the film being placed in a wallet. To physically fit into a standard wallet, the badge needs to be trimmed to the edge. Historical IDs are one of our areas of expertise, and we double-checked drivers license dimension standardization before making this decision (since drivers license dimensions dictate wallet designs). Drivers license standardization did not happen all at once, but in California it happened in 1976, years before filming began for Blade Runner, which means it is significantly more likely that the badge had to be trimmed to its edge in order to fit into the wallet with the transparent ID window used for the prop.
Furthermore, we found a quote from Blade Runner's graphic designer, Tom Southwell, on the website propsummit.com where he did a Q&A. He explained that the property master, actor, and director worked together to build the wallets. Therefore, the most screen accurate version of Rick Deckard's ID is one that fits into a standard wallet, which means it needs to be trimmed to the edge of the artwork. While it is true that the only surviving original ID is a clip on, this has nothing to do with Rick Deckard's wallet ID.
Another concern people have is that we might make hundreds or even thousands of badges based on there being a large stack of paper seen in the Tested video. Rest assured we are not making that many badges, the stack of cardstock may look tall, but cardstock is thick and that stack only printed 300 total badges, and while that number may seem high, we want to stress that printing the ink onto the cardstock is just the first step in a lengthy process of producing these badges. Out of 300, only 150 of those were even deemed good enough to move onto the next stage. The reason so many are lost is because the process of aligning the cuts uses up a good amount of the stack. In the photo posted by another user, a misprint is seen on the top of a "finished" stack where the yellow is misaligned. Misprints like that are very common with multiple colors and double-sided printing, and this print has both. Once the alignment is right, then the rest of the stack can be printed fairly easily, but it is nevertheless a lengthy and skilled process to get there, and why printing using this process is so pricey (and gets cheaper the more you order). This is why, before digital printing, it was typical to print extras of everything. This is especially true with something like the Blade Runner badge where each future step in the construction process could ruin it. In all, nine machines are used to make the badges and the printing press is just the first step. Through the construction process, many badges were deemed unsellable due to ink splotches, crooked text, bad handwriting, or dust getting stuck beneath the lamination.
As you can see, the original 300 print-run quickly dwindles. We printed enough to ensure at least 75 badges for the RPF community, with extras reserved for our personal clients.
As much as we have enjoyed stepping into the world of memorabilia recreation, we are a small company and our main focus is producing cinema inserts for current film productions. We've been open 108 years, and this is the first time we've opened up to the public for something. It is only due to the WGA and SAG strikes that we've have the time to produce the badges. After the excitement of this amazing project, and hopefully the successful end to the strikes in favor of the writers and actors, we will return full-time to cinema inserts. We have enjoyed making the badges and have received so many amazing responses from the community at RPF. From one part of the prop community to another, thank you all for being so passionate.
And last but not least, to the user's friend who said that Adam Savage should have stayed at Earl Hays Press, we say, "yes please!". We thoroughly enjoyed his visit to our shop and would be only too happy to host him again.
— the Earl Hays Press team