Post by Branjita on May 5, 2021 10:57:16 GMT -6
This content is directly copied from a website that no longer exists. This info deserves to "live" so I am posting it here so it doesn't disappear forever (which... as far as I know... it already has). Credit to the original author:
Galaxy Collectibles (originally located at www.galaxycollectibles.com/category-s/108.htm). There were photos associated with this article, but I don't have them.
This article was about Star Wars figures, not DBZ figures, so the exact process was not likely the exact same, but it's a good guide. This is mostly applicable to 1980s - 2000s figures. SHFiguarts and other more recent figures are typically designed on computers, so the process is much different I assume.
The creation of an action figure is a very detailed process and requires a number of steps from an idea to toy shelves. This process is explained below to help identify types of pre-production items.
Phase I - Conceptual Design
This is where it all begins! The design team will pitch ideas with concept boards, hand made figures, hand made packaging, etc. These pieces are generally very primitive and do not have the quality of a production item.
Phase II - The Figure Creation
In this phase, sculptors will create wax sculpts for the action figure. They typically use a special tool to add or subtract wax from the sculpt. The wax used is a relatively hard substance and retains a fair amount of detail. The limbs are typically pinned together. From this sculpting input, a pattern drawing is made. As changes are requested to the wax sculpt, a final wax is made.
Next, a silicone mold is made from the wax sculpt and a resin will be poured into the mold to create a hardcopy. Hardcopies are also pinned together and will retain close to the same level of detail as the wax sculpt. The hardcopies can be painted to give a quick feel for what the actual production figure may look like. They are used to make final changes and for displays at the Toy Fairs.
The final wax is used to generate a hardcopy. Using a silicone mold process, resin is poured into the mold to produce the hardcopy figure. Hardcopy figures are also typically pinned together for articulation.
Once approved, tooling is made to produce steel molds for the final injection mold process. First shots are generated from the steel molds using a plastic injection mold process. In this stage, they test for fit, form, function and safety. First shots can be found in a variety of colors that may or may not match the final color scheme of the action figure. Early versions can be found without copyright markings and/or peg holes. Next, decomasters (aka paint samples) are made to assure that the final paint will match the intended design. Final engineering pilots (FEP) are generated as the last phase of the figure creation process. Once approved, the production figures will be produced in mass quantities also using the injection mold process.
Phase III - Packaging
Early conceptual designs and/or hand-made proofs are used to make a final design. Once a final design is approved, a proof sheet or card is generated. First shots and paint samples are often used to generate Engineering Pilots (EP). Engineering Pilots are generated to test the blister design of the figure. The blister is the clear plastic that is used to mount the figure to the card back. Engineering pilots may be modified to ensure that the figure and accessories are posed and layed out properly. Examples can be found mounted to a variety of card stock.
Phase IV - Quality Control
In this phase, some final changes can be submitted to the design team for quality control and final approval. These figures can be found with a paper sign-off tag taped to the card. In some cases, notes can be made to make some desired changes.
There's another website (Prototype Archives) that has a similar article. It is still online on www.prototypearchives.com/concept-to-toy-shelves but I'm copying it over in case it disappears someday. The images on their site work, but since they are Star Wars related, I don't see any benefit to copying them over on here.
Like I said above, this process is likely different than what Bandai, Irwin, Jakks Pacific, and other '80s-'00s figure companies were doing, but it's a good guide.
Concept to Toy Shelves
There are many steps involved in the creation of action figures. This guide will help describe the process and define terminology used in the industry. Each stage in the product development process is critical for both the licensor and licensee. At each stage, specific features of the product should be reviewed. The following development stages are delivered by Hasbro to Lucasfilm Ltd. (LFL) for approval.
Phase I - Conceptual Design
Toy makers are given the task to develop toys that are safe, durable and fun to play with. In order to decide what to make, designers pitch different ideas and concepts. Concept boards are developed to communicate the overall goal of the toy for development. They may include movie scrap, photos and/or other rendered material where needed. Toy features should be considered for approval or rejection at this point.
Phase II - Figure Creation
Sculpt input drawings will only be submitted when full detailed scrap on a given character is not available. If detailed scrap is available, input for figures will include the LFL supplied movie scrap that supports the outfit, and a representation of the pose. Pattern drawings are created to give general dimensions of the figure. The sculpt will be used to get feedback of any potential changes. Once approved, a sculptor will create a wax sculpt for the figure. The wax sculpts are delivered to LFL in person and compared to their inputs, when applicable. The figure's detail & pose should be considered at this time. In some cases, secondary sculpts (capes, jackets, etc.) may be submitted separately. Very specific direction from LFL for any revisions will be necessary when the wax is presented.
Once the final wax and/or accessory pattern is approved, Hasbro will proceed to creating a Deco Master. A Deco Master is a is the first fully decorated 3-D image that is delivered to LFL. The Deco Master is often referred to as a painted hardcopy. A hardcopy is generated from the final wax by using a 2-part silicone mold process. This provides a relatively quick resin "hard" copy to be made. The hardcopies are fitted with metal or plastic pinned joints to allow some basic movement. The Deco Master hardcopy is hand painted to represent what the figure would look like. In some cases a "complete" Deco Master may require additional support (i.e. soft goods or new process) from the Orient office/vendor. When this occurs, with agreement from both Hasbro and LFL, a final pre-production sample of the product will be submitted to LFL for approval before the item goes into final production.
The Orient office/vendor will create steel molds used for the injection mold process and will ultimately be used to mass produce the figures. Injection molding machines use small plastic beads that are melted and injected into the molds at a high pressure. First shots prototypes are produced and are used for samples. The figure can go through another approval process to ensure safety, fit, form & function. These prototype figures are often created in random colors. Early versions may not have any copyright information. Once approved, the molds may be modified to include peg holes and/or copyright markings. More test shots can be produced at this point which can be used for fit, form, function and safety. Paint samples of the figures are created to ensure the proper paint scheme. These samples are also known as Final Engineering Pilots (FEPs). Once approved, the figures will be released for mass production.
Phase III - Packaging Design
When a new segment or line is created (Expanded Universe, Classic transition, Episode I), the team will develop a package line look with the help from the Packaging Department and Studio. Line looks will be presented in person to LFL to hear reactions and comments to the direction. Once approved, the team will proceed to package development for individual items in the line. In some cases, the line look might also apply to a segment (e.g. Epic Force, Freeze Frame slides). In those cases, LFL will have an upfront opportunity to look at the segment for structure and graphic detail. The package design often begins with a rough preliminary art design. Graphic artists will generate packaging concepts. Some of these concepts are printed and made into hand-made conceptual mockups used in the submission process. The line look is evaluated by whether or not the look meets the packaging objectives. Evaluation should include fit with the balance of the brand, consistency with brand character, and clarity of communication of the key elements. The package layout may include early photos for design purposes. Final photography will be made once the layout is approved.
Once the final layout is approved, a final film/chromalin is produced. This two-dimensional final package digital ink jet "chromalin" will be submitted to LFL before going to press with the package. The chromalin will reflect all comments made at the package layout stage. It represents accurate production color, or indicates any requested changes.
Phase IV - Final Production Samples
The Orient office/Vendor will create the final packaging to produce final production samples. During this process, Engineering Pilots (EPs) are created to offer a first-look at how the figure and accessories are displayed in the plastic blister. EPs are also known as packaging mock ups. Once approved, final production samples are submitted to LFL for final approval. These samples will be actual production sent to the States from Orient/Tijuana. The sample is evaluated by LFL to confirm that the product and package contain the same quality as all submissions throughout the item's development, including any items noted as "approved with changes" at the previous stage (deco master, pre-production sample, final film). Once approved at this stage, the item's development is complete and the figure is sent to production. Toys are sent to distribution and ultimately to retailers for purchase.
The Irwin and Jakks process was likely something like this timeline I've created below, but this is just my opinion/guess.
Galaxy Collectibles (originally located at www.galaxycollectibles.com/category-s/108.htm). There were photos associated with this article, but I don't have them.
This article was about Star Wars figures, not DBZ figures, so the exact process was not likely the exact same, but it's a good guide. This is mostly applicable to 1980s - 2000s figures. SHFiguarts and other more recent figures are typically designed on computers, so the process is much different I assume.
The creation of an action figure is a very detailed process and requires a number of steps from an idea to toy shelves. This process is explained below to help identify types of pre-production items.
Phase I - Conceptual Design
This is where it all begins! The design team will pitch ideas with concept boards, hand made figures, hand made packaging, etc. These pieces are generally very primitive and do not have the quality of a production item.
Phase II - The Figure Creation
In this phase, sculptors will create wax sculpts for the action figure. They typically use a special tool to add or subtract wax from the sculpt. The wax used is a relatively hard substance and retains a fair amount of detail. The limbs are typically pinned together. From this sculpting input, a pattern drawing is made. As changes are requested to the wax sculpt, a final wax is made.
Next, a silicone mold is made from the wax sculpt and a resin will be poured into the mold to create a hardcopy. Hardcopies are also pinned together and will retain close to the same level of detail as the wax sculpt. The hardcopies can be painted to give a quick feel for what the actual production figure may look like. They are used to make final changes and for displays at the Toy Fairs.
The final wax is used to generate a hardcopy. Using a silicone mold process, resin is poured into the mold to produce the hardcopy figure. Hardcopy figures are also typically pinned together for articulation.
Once approved, tooling is made to produce steel molds for the final injection mold process. First shots are generated from the steel molds using a plastic injection mold process. In this stage, they test for fit, form, function and safety. First shots can be found in a variety of colors that may or may not match the final color scheme of the action figure. Early versions can be found without copyright markings and/or peg holes. Next, decomasters (aka paint samples) are made to assure that the final paint will match the intended design. Final engineering pilots (FEP) are generated as the last phase of the figure creation process. Once approved, the production figures will be produced in mass quantities also using the injection mold process.
Phase III - Packaging
Early conceptual designs and/or hand-made proofs are used to make a final design. Once a final design is approved, a proof sheet or card is generated. First shots and paint samples are often used to generate Engineering Pilots (EP). Engineering Pilots are generated to test the blister design of the figure. The blister is the clear plastic that is used to mount the figure to the card back. Engineering pilots may be modified to ensure that the figure and accessories are posed and layed out properly. Examples can be found mounted to a variety of card stock.
Phase IV - Quality Control
In this phase, some final changes can be submitted to the design team for quality control and final approval. These figures can be found with a paper sign-off tag taped to the card. In some cases, notes can be made to make some desired changes.
There's another website (Prototype Archives) that has a similar article. It is still online on www.prototypearchives.com/concept-to-toy-shelves but I'm copying it over in case it disappears someday. The images on their site work, but since they are Star Wars related, I don't see any benefit to copying them over on here.
Like I said above, this process is likely different than what Bandai, Irwin, Jakks Pacific, and other '80s-'00s figure companies were doing, but it's a good guide.
Concept to Toy Shelves
There are many steps involved in the creation of action figures. This guide will help describe the process and define terminology used in the industry. Each stage in the product development process is critical for both the licensor and licensee. At each stage, specific features of the product should be reviewed. The following development stages are delivered by Hasbro to Lucasfilm Ltd. (LFL) for approval.
Phase I - Conceptual Design
Toy makers are given the task to develop toys that are safe, durable and fun to play with. In order to decide what to make, designers pitch different ideas and concepts. Concept boards are developed to communicate the overall goal of the toy for development. They may include movie scrap, photos and/or other rendered material where needed. Toy features should be considered for approval or rejection at this point.
Phase II - Figure Creation
Sculpt input drawings will only be submitted when full detailed scrap on a given character is not available. If detailed scrap is available, input for figures will include the LFL supplied movie scrap that supports the outfit, and a representation of the pose. Pattern drawings are created to give general dimensions of the figure. The sculpt will be used to get feedback of any potential changes. Once approved, a sculptor will create a wax sculpt for the figure. The wax sculpts are delivered to LFL in person and compared to their inputs, when applicable. The figure's detail & pose should be considered at this time. In some cases, secondary sculpts (capes, jackets, etc.) may be submitted separately. Very specific direction from LFL for any revisions will be necessary when the wax is presented.
Once the final wax and/or accessory pattern is approved, Hasbro will proceed to creating a Deco Master. A Deco Master is a is the first fully decorated 3-D image that is delivered to LFL. The Deco Master is often referred to as a painted hardcopy. A hardcopy is generated from the final wax by using a 2-part silicone mold process. This provides a relatively quick resin "hard" copy to be made. The hardcopies are fitted with metal or plastic pinned joints to allow some basic movement. The Deco Master hardcopy is hand painted to represent what the figure would look like. In some cases a "complete" Deco Master may require additional support (i.e. soft goods or new process) from the Orient office/vendor. When this occurs, with agreement from both Hasbro and LFL, a final pre-production sample of the product will be submitted to LFL for approval before the item goes into final production.
The Orient office/vendor will create steel molds used for the injection mold process and will ultimately be used to mass produce the figures. Injection molding machines use small plastic beads that are melted and injected into the molds at a high pressure. First shots prototypes are produced and are used for samples. The figure can go through another approval process to ensure safety, fit, form & function. These prototype figures are often created in random colors. Early versions may not have any copyright information. Once approved, the molds may be modified to include peg holes and/or copyright markings. More test shots can be produced at this point which can be used for fit, form, function and safety. Paint samples of the figures are created to ensure the proper paint scheme. These samples are also known as Final Engineering Pilots (FEPs). Once approved, the figures will be released for mass production.
Phase III - Packaging Design
When a new segment or line is created (Expanded Universe, Classic transition, Episode I), the team will develop a package line look with the help from the Packaging Department and Studio. Line looks will be presented in person to LFL to hear reactions and comments to the direction. Once approved, the team will proceed to package development for individual items in the line. In some cases, the line look might also apply to a segment (e.g. Epic Force, Freeze Frame slides). In those cases, LFL will have an upfront opportunity to look at the segment for structure and graphic detail. The package design often begins with a rough preliminary art design. Graphic artists will generate packaging concepts. Some of these concepts are printed and made into hand-made conceptual mockups used in the submission process. The line look is evaluated by whether or not the look meets the packaging objectives. Evaluation should include fit with the balance of the brand, consistency with brand character, and clarity of communication of the key elements. The package layout may include early photos for design purposes. Final photography will be made once the layout is approved.
Once the final layout is approved, a final film/chromalin is produced. This two-dimensional final package digital ink jet "chromalin" will be submitted to LFL before going to press with the package. The chromalin will reflect all comments made at the package layout stage. It represents accurate production color, or indicates any requested changes.
Phase IV - Final Production Samples
The Orient office/Vendor will create the final packaging to produce final production samples. During this process, Engineering Pilots (EPs) are created to offer a first-look at how the figure and accessories are displayed in the plastic blister. EPs are also known as packaging mock ups. Once approved, final production samples are submitted to LFL for final approval. These samples will be actual production sent to the States from Orient/Tijuana. The sample is evaluated by LFL to confirm that the product and package contain the same quality as all submissions throughout the item's development, including any items noted as "approved with changes" at the previous stage (deco master, pre-production sample, final film). Once approved at this stage, the item's development is complete and the figure is sent to production. Toys are sent to distribution and ultimately to retailers for purchase.
The Irwin and Jakks process was likely something like this timeline I've created below, but this is just my opinion/guess.
clay or other sculpting medium without articulation
↓
clay or other sculpting medium with articulation and dowel rods holding the pieces together
↓
hardcopy prototype typically with dowel rod articulation still (and bigger than the production figure)
↓
test shot without copyright info on it and often a little different sculpt from the production figure, but sometimes with production style articulation (may or may not be production plastic... might still be a hardcopy)
↓
test shot suitable for painting and using for promotion purposes (cracker actually used to do some painting for Jakks Pacific and could give his take on the process (and correct my errors))
↓
test shot made of a production style plastic (usually random colors and sometimes with permanent marker markings from factory workers on it) in the same size as the production figure, articulation like the production figure, and copyright info on it
↓
test shot made of production colored plastic (looks just like a production figure pulled off the production line before it got painted... and it might actually be that... a stolen figure)
↓
production figure (ones that pass quality control get packaged, ones that fail QC (due to obvious paint defects, casting problems, etc.) get thrown away, stolen, and/or sold without a package by sellers in Hong Kong/China as "used figures" when they are actually "production rejects")