Manufacturing Custom Action Figures with Happy Worker

Design & Creative Decisions for Custom Action Figures
Turning Brand Characters&Mascots into Custom Dolls

Manufacturing Action Figures & Custom Dolls with Happy Worker

Just The Basics

Design & Creative Decisions

Prototyping & Manufacturing

On this page you’ll find more information about the design decisions that Happy Worker makes together with our clients to design custom action figures & custom dolls.

 

 

 

 

 

 

 

Doll & Action Figure Characters
Choosing the Right Toy Characters

Happy Worker enjoys pushing new boundaries in toys and figure design. All sorts of characters can be fashioned into well executed dolls and action figures. Figures of all types and sizes are possible - from static “in-action” figures, to figurines, mini figures, articulated & jointed figures, and figures with lights and sound chips.

First, the right character is chosen. In some cases clients come to Happy Worker with finished designs and we’ll convert the character into the most authentic action figure or doll. Other times our clients may have only a general feel for the character or a business problem to solve.

Our creative teams will collaborate to co-conceive and develop the character, working from rough concepts to finished designs. Character integrity is integral, as are our client’s overall branding and program goals.

 

 

Action Figure & Doll Design Decisions
We Work Happily to Get All the Details Right

Next it’s time to decide what toy figure format will best bring the character to real toy life. A number of creative toy decisions are made in sync with the concept, including:

• Size
• Materials & Colors
• Jointing, Limbs & Toy Articulation
• Accessories
• Branding
• Packaging
• Distribution
  
  

Happy Worker’s toy experts will recommend the best design to suit the toy and collectible’s purpose, audience and business goals. Once all the decisions are made a Happy Worker illustrator will create final action figure “control artwork”, or blueprint designs that will be used for toy prototyping.

 

Action Figure Sizes & Scales
Rightsizing – Best Toy Size for Your Audience

Happy Worker can create action figures & dolls of almost any size, from a miniature size as small as an inch or two (5 – 10 cm) to giant figures standing several feet. As with everything there are different sizes for different uses – and bigger is not always better. We will recommend the best size of figure for your character, the intended use, and program goals.

Common figure and doll sizes include:

• 1” – 3” Mini Figures
  Small art toys and figures like “Mini-Mates”, “Smurfs” or “Lego” people

• 3 ¾” Figures
  Popular size for Custom “Star Wars” or smaller “G.I Joe” figures

• 6" Figures
  Common modern super hero size, and best for desk-sized figures

• 8” Figures
  Custom “Mego” action figures

• 11.5” Figures
  Custom “Barbies” and dolls

• 12" Figures
  Custom “G.I. Joe” (traditional/retro scale) figures

• …or bigger – 18" Figures
  Giant Figures, “Life Size” Replicas, or larger Display pieces,

Best Size for Custom Corporate Action Figures

Office and desk-friendly sizes for corporate action figures are commonly 3 to 8 inches (7.5 to 20 cm) tall. Action figures over 8 inches (20 cm) tall usually have a larger footprint, and are not as suitable for easy “desk top” or office display.

 

Materials&Colors
We only use the best stuff. And the right stuff.

We work with a variety of plastics and paints, using the best toy materials for program goals:

• Plastics - We select from common toy materials like vinyl or PVC (poly vinyl chloride), ABS (acrylonitrile butadiene styrene), PS (polystyrene) and others depending on the item and its function.
• Paint Colors - Any imaginable combination of colors can be used to create the plastic and paint for your custom doll. We can readily match PMS colors.
• Other Materials – We can incorporate other materials into the toy, such as magnets, plush and fabrics, metal, wood, etc.

 

Toy Joints&Limbs
Putting the “Action” in Action Figure

Static Figurines - some figurines are static statues without any movement. Also called “in-action” figures, these static figurines are best when character integrity is most important or where it’s better not to have moving parts. In-Action Figurines are also popular for simple smaller figures (think “Smurfs” figures), and for collectible figures that are meant for display only.

Poseable Action Figures - have a few to many “articulation points”. Articulation points are poseable joints and limbs that move, rotate or disconnect. The simplest action figures have as few as 1 articulation point (for example, head/neck turns) or 3 articulation points (head/neck turns, and shoulders rotate or hands turn).
Some of our dolls and action figures are highly poseable and have 14+ points of articulation, so that head, shoulders, elbows, hands, waist, hips, knees, and feet can all be moved and posed.

Balancing Form with Function - in all cases we design toys carefully to hide as much of the engineering and joints into the doll sculpture as possible.

 

Action Figure&Doll Accessories
Heroic Tools and “Weapons”

What would “Superman” be without his cape, “Wonder Woman” without her golden tiara, “Batman” without his gadgets, “G.I. Joe” without his weapons, and “He-Man” without his power sword?

Every great action figure, toy hero and heroine needs their own trusty accessories to compliment his or her super powers.  We’ll work together to create miniature accessories that are right for your custom doll, character and brand:

• Materials - While most accessories are made of plastic, they can created from fabric, metal, magnets, cardboard, and many other materials.
• Number of Accessories - Custom action figures and custom dolls can have any number of accessories. Some are created without accessories and others have a few, 5, 10 or even more trusty tools of the trade.
• Compatibility - All accessories are engineered alongside the toys to be completely compatible

 

Fun toy accessories we’ve created for action figures and dolls include:

• Replaceable heads and faces to play up multiple moods and personalities
• Magnetic accessories that stick to different parts of an action figure
• Tiny briefcases and toolboxes that open and close
• Changeable hands and shoes
• Wearable mini toy costumes
• Custom figure stands and displays

 

Logos & Branding

Depending on the complexity of the design, branding and logos can either be sculpted or engraved into the figure, or applied almost anywhere on the surface of the action figure or its accessories through painting and imprinting.

 

Action Figure Packaging
Fun Content & Unwrapping Reveals

An action figure’s package adds to the value and gifting experience.  It’s also an excellent canvas for branding and messaging.  Each packaging style has its advantages – some are best for collectors, others for retail shelves, while some packaging styles are best for environmental sustainability or reduced shipping expenses.

Popular styles of retail, gift and collector packaging for action figures and dolls:

• Blister Cards - Cardboard backing with a transparent plastic bubble sealed on top
• Card Gift Boxes - Also referred to as “blind boxes”, made of recyclable thick card stock
• Clamshells – Similar to blister cards but made entirely of plastic; can be permanently sealed or re-sealable so collectors can remove & replace their action figures
• Window Boxes – Card or cardboard gift boxes with a see-through plastic window on front; can also have a foldable cover on top
• Polybags – Smallest and lightest possible packaging, these printed and sealed plastic bags are an economical choice and have the smallest transportation footprint
• Tin Gift Boxes – Made of tin plate, can be formed, printed, embossed into original shapes
• Acrylic Display Cases – For higher end collectibles, these thick UV-protective cases are a classy display showcase
• New & Unique - We're always interested in experimenting with new packaging designs and materials

 

First we help our clients choose the best style of packaging that meets their goals. Then the design is created, either by Happy Worker or by our clients’ creative team. If Happy Worker is acting in the supporting role for the package design we supply full graphic templates, assist with heroic action figure package copy, and provide required toy package content.

 

Corporate Gifting & Distribution
Design with Distribution in Mind

When selecting the right packaging style it’s important to consider who will receive the corporate action figures or dolls, as well as when, where and how they’ll receive them.

• Direct Mail – Toy packaging and mailer box can be tightly integrated into complete direct mail pieces
• Trade Shows & Events - Package and custom action figure can be designed to be easy to carry around a trade fair floor
• Retail Options - Including common retail product options like hang tabs or dangling tags, UPC codes, stickers, and point-of-purchase displays
• Marketing Literature - Including reply cards, brochures and sales rep business cards either attached to, inside, or as part of the packaging

 

Next Steps

 

 

 

 

Our Work

Insurance Agent Action Figures

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Service Guy Vinyl Figure

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Super Leasing Pro Action Figure

More original custom toys & gifts >>

• Figurines
• Plastic Figures
• Dolls
• Designer Figures
• Vinyl Toys
• Mini Figures

 

Fun Facts - Safeco

The most challenging engineering component for this project was a lasso accessory for Agent Van Fleet, a heroic insurance agent who hails from Texas. While other accessories were created digitally using CAD rapid prototyping, the lariat required a more hands-on approach. After going through a dozen different hand sculpted models, we finally had one that we felt had the right balance of form and function… and were able to rope up the final design and start production.

See the work...