The Project:

Sally’s Apizza, one of the oldest pizzerias in America, approached AK Studios as they embarked on their franchising journey, planning to open over 30 new locations nationwide. Our task was to recreate their nearly 100-year-old oven for these new establishments.

To meet modern standards and requirements, we were asked to replicate, update, and adapt cast iron components from their flagship restaurant to fit a UL-approved drop-in oven system. The process began with carefully disassembling the original oven into its individual cast parts. Each piece was meticulously documented and 3D scanned to ensure accuracy and preserve the authenticity of the original design.

We recreated all the parts in CAD and produced scale 3D-printed models. From there, we developed and tested multiple prototypes until achieving a fully functional design.

We managed the entire process, from scanning and design to development, sourcing, and production oversight. This included creating detailed installation instructions, collaborating with foundries across the U.S., and designing custom machining jigs. Our goal was to ensure the team at Sally’s could focus on what they do best—making delicious pizza.