Custom Action Figures Prototyping & Manufacturing
Happy Worker’s Step-by-Step Action Figure Making Process

Manufacturing Action Figures & Custom Dolls with Happy Worker

Just The Basics

Design & Creative Decisions

Prototyping & Manufacturing

On this page you’ll find an overview of how Happy Worker prototypes and manufactures custom action figures and custom dolls. If you’re the detailed oriented type and like to know how the toy magic happens, then this page is for you!

 

 

 

 

 

 

Sculpting and Prototyping
From Concept to Action Figure Prototypes

Custom action figures begin life as rough concept drawings. Through an iterative design process that’s full of fun excitement and craftsmanship we turn sketches into final toy prototypes that are used to mold and produce the action figures.

1. Rough Illustrations
   Character concept sketches are created either by hand or digitally, noting accessories, special features and toy functions. This uncolored concept art helps guide design & engineering decisions.

2. Final Concepts
   With client approval Happy Worker creates clean “final” toy concepts. This is an evolved colored version of the action figure and its accessories. The color palette is still draft and will be finalized in the next step.

3. Toy Control Art
   This series of carefully illustrated turnarounds shows the figure or doll from multiple views and angles. Also called ‘Toy Control Art’, it acts as blueprints for sculpting and engineering. During this step we’ll also create painting color guidelines with Pantone PMS numbers.

4. Packaging Mockups
   Packaging design runs parallel to toy prototyping. If Happy Worker is designing the package we’ll create draft mockups and provide updates and review stages. If our client is designing the package we’ll supply a template with all required information and graphics, plus copy and design tips.

5. Prototype Modeling
   Physical prototyping begins! Each action figure or doll body part and accessory is sculpted or modeled, either by hand or digitally by 3D CAD. Once the initial rough sculpture takes shape the more intricate details are added on top, until a fully detailed & working prototype is finished. The first prototype is normally uncolored/unpainted and without branding, and made in a different material than the final toy.

6. Production-Ready Prototype
   Final engineering is completed, and the parts are converted to a production-ready prototype that is ready for tooling and molding. This is the last opportunity to make any changes to the 3D design or shape of the action figure or its accessories.

7. Tooling & Molding
   From the production-ready prototype, steel tools and molds are created, which will be used during production to make all plastic action figure & doll parts.

8. Shipping Planning
   With approval of production-ready prototype we’ll reconfirm delivery and shipping dates and begin to make the necessary logistics preparations.

9. Packaging Approval
   Final packaging copy & artwork are approved by our clients’ design, marketing and/or legal teams. If desired retail UPC barcodes are assigned and included.

10. Painted Prototype (“Paint Master”)
    The action figure prototype is painted by hand, normally by air brushing. This is also called the “Paint Master”) and serves as paint guidelines for the toys during production.
    
    
11. Test Toys (“Engineering Pilot”)
    The first action figures & doll samples in their final materials, these toys are made on a test production line. Also called “Engineering Pilot” or “First Shots”, they’re unpainted and are used to double check engineering and workability of the final figures.

12. Packaging and Artwork Proof
    We’ll create several proof samples of the packaging to ensure that the colors are correct and alignment is perfect.

13. Finished Action Figures & Dolls (“Production Samples”)
    We’ll send final samples of the toy in its packaging prior to production start, to confirm that the final action figures and custom dolls meet quality expectations.

 

Manufacturing… it’s Toy Making Time!
Our Action Figure & Doll Production Process

After the action figure prototype is completed and approved, and the production tools and molds are created, it’s toy-making time! At a high level, custom action figure manufacturing includes the following steps: 

1. Action Figure Part Casting
   The various action figure parts and toy pieces are made, often by injection or by rotocasting. Plastic pellets are melted and injected into the mold. After the plastic cools (normally a matter of seconds) the mold is opened and parts are removed and separated.

2. Figure Painting
   Action figure body parts and accessories are painted by hand, normally as individual parts. Expert painters apply paint through a combination of air brushing using 3D stencils and careful hand brushing, using the Paint Master and approved action figure production samples as paint guidelines.

3. Toy Finishing & Assembly
   All painted parts are assembled together into complete action figures. This involves ‘popping’ parts together, adding plastic rivets or metal screws, or in some cases gluing or sealing parts together.  While Happy Worker manufactures action figures in quantity, each action figure is finished and assembled by hand.

4. Packaging
   The newly finished action figures and their accessories are placed neatly into their packages, and the packaging is assembled and finished.

5. Action Figure Quality Control
   Before being packed for shipping, action figures are checked again for quality assurance against our toy quality control checklist. Additional toy quality control testing & safety tests are also performed.

 

Toy Quality Control & Safety Testing
First Plan, then Test to Make Sure

All action figures Happy Worker makes as well as their raw materials are subjected to safety and quality testing.  During manufacturing and again before packaging, each doll is compared against the Quality Control Checklist, which includes all key product requirements and specific details to watch over during production. Analytical quality exams are also performed.

Additional safety testing is required for toys intended or marketed for children and teens less than 15 years old. Happy Worker works with certified toy testing labs that perform U.S. CPSC, CPSIA, ASTM and other tests as required by each country and region to meet and exceed federal and international safety standards.

Logistics, Delivery & Gifting Distribution
Delivery of Custom Action Figures & Custom Dolls

Whether it’s for an event, trade show or retail launch, we’re experienced at delivering action figures around the world, from large shipments to small, by sea, air, truck, or courier. We can also kit toys together with other items and manage complex distribution requirements.

Together we’ll discuss your distribution needs, and then work with our shipping and logistics partners to deliver the action figures happily on time and in good condition.

For super important rush shipments – if we agree to produce a rush order (e.g. action figures less than 20 weeks), then please see our Time critical rush shipping – the fine print for additional information to be aware of.

Extra Step - Happiness Now & Forever

We’re just as excited about your custom action figures and custom dolls as you are. And we want to make sure your new toys aren’t just delivered to the quality we both expect, but that they achieve the goals of your program and business.

We followup both during launch and a few weeks or months after launch to get your feedback – and feedback from toy recipients – to make sure we’re achieving toy and program goals. In our spirit of constant betterment, any potential improvements to products and processes are captured so every new custom toy and gift is our best item ever.

 

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