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The Spark Generator developed by 
Special Effects, Inc. is a non-pyrotechnical device providing a controllable,
reliable, variable, and economical shower of sparks, while improving safety on the set. It is currently being used for
motion picture, amusement park, and stage production special effects.
The Spark Generator is available in two standard configurations.
Both models may be rented through Creative Effects.
Aluminum Wire Sparks
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Steel Wire Sparks
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In 1992, Phil Cory developed a prototype of a non-pyrotechnical spark
generator that creates a continuous spray of sparks. The generator
provides fine directional control of the sparks, from a few inches to
showers over 30 feet. It can be used on both stationary and moving objects
to simulate both electrical and abrasive spark sources.
The generator consists of two spools of wire that are electrically
oppositely changed. The charged wires are guided through a specially
developed tip assembly. Much like an arc welder, when the ends are brought
together in the tip, sparks are produced. The wires are continuously feed
from the spools to maintain the shower for as long as desired. A stream of
air blowing through the tip assembly toward the point of electrical
discharge disperses the sparks in a controlled manner. The current levels
control the quantity of sparks, while the air pressure controls the size
and duration of the shower. The use of different types and sizes of wire
control the size and color of the sparks.
The spark generator is battery powered and electrical timed. Since it
is electrically controlled, it can be stopped and started on cue. The
controls provided for timing, duration, direction, and intensity,
inherently allow for a much higher degree of safety. Since it is
non-pyrotechnical, non-licensed personnel can operate it.
The spark generator has been used on several productions. The first was
in June of 1992 on "Dr. Giggles"
, where it was used to simulate an electrical short during an
operating room sequence. Another example, can be seen in "The Amelia Earhart Story", where it was used to simulate an airplane engine
malfunction. Since then the generator, including the tip assembly and
electronics have undergone continuous development and perfection. The
system was modified for portability before its use on "Heart and Soul".
After "Heart and Soul", the electronics were updated to their
current state.
The spark generator is currently being used at the GM-Test Track
Display at Epcot Center in Florida. Universal Studios is installing
several in their Universal Studios Tour attraction.
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Special Effects, Inc.