Figures, promotional mascots and educational models are now commonly found in pop culture, advertising and schools. But have you ever thought about how these impressive and strong figures are made?
Creating a figure mixes art with engineering and involves a number of steps from idea to finished product. Due to improvements in manufacturing such as PVC injection molding, making quality, scalable and inexpensive figures is now much simpler. In fact, the global plastic injection molding market is expected to grow from $403.85 billion in the year 2024 to $561.58 billion by 2032.
This article will take us through the entire process of making a figure, from starting with a concept to producing many copies.
1. Conceptualization and Design
All figures in sculpture start with a concept in mind. Depending on your inspiration, you must start by figuring out the look, size, purpose and audience of your design.
You will typically find yourself doing the following during this phase.
- A number of rough sketches or computer images showing the front, back and side of the object
- Scale choices such as 1:6 or 1:12
- Notes about the materials used, articulation when needed and accessories or base stands
Most professional designers rely on tools such as Adobe Illustrator or Photoshop, to craft clear concept art. When deciding on commercial products, branding and attractiveness of the market are considered.
2. 3D Modeling
Once you have your concept, the next action is to build a 3D model using ZBrush, Blender or Autodesk Maya.
Designers are able to do the following because of 3D modeling:
- Sculpt the expressions on the face, the materials on the clothing and the props used by the actor
- Remember to plan the way the figure’s parts will move if you want it to be poseable
- Finalize the files so that they are ready for a prototype or a mold
Every step after this is guided by digital design. The use of computer-aided design guarantees details are replicated perfectly and made easy to change before production.
3. Prototyping
Once the 3D model is finished, you should make a real prototype. Usually, 3D printing technology is used for this purpose. The resolution in resin or polymer prints allows all the small details in your design to be included.
It is important to use prototypes because they:
- Ensure the design is correct when measured in real dimensions
- Check how the joints on articulated figures work
- Also, ask the people attending the preview for their opinions
Sometimes, the prototype is made several times and only after all changes are made is it approved for mass production.
4. Mold Making
When the prototype is approved, the first major step after that is creating the mold for mass production. It is at this stage that the skills of an injection molding factory are most important.
Injection molding is when molten plastic is pushed into a mold cavity during manufacturing. Once everything is cool and solid, the material adopts the form of a mold.
PVC injection molding is the usual process used for making figures and is used for about 62% in PVC products. Polyvinyl Chloride (PVC) for its long-lasting properties, low price and many uses is in demand.
The following activities are included in mold-making:
- Manufacturing steel or aluminum mold cavities using a 3D model for the design
- Make sure the mold is perfect to give the best output
- Preparing several mold parts to handle the design’s complicated shapes
If a figure is not simple, a single mold could be made up of several interconnected pieces so removal of the product is easy.
5. Injection Molding Production
Now, the sculpture is produced in large quantities using PVC injection molding. This is done by:
- Heating PVC pellets until they become a liquid.
- Adding the liquid PVC to already made molds and sealing them under a lot of pressure.
- Let the molds cool so the PVC hardens.
- Removing the shape of the molded pieces from the cavity.
- Creating one mold only takes a few minutes and allows you to make many identical pieces in a short time.
The ability of injection molding to repeat the same result is very important for companies making collectible figures that need exact details.
6. Assembly
Figures most often consist of separate parts such as heads, arms, legs and accessories, instead of being made from a single mold. Following the PVC injection molding, every part is assembled to build the full figure.
This process usually consists of:
- Getting rid of any extra plastic at the edges to make them clean.
- Assembling your creation by using pegs, glue, screws or joints that snap together.
- Adding supports or magnets to help maintain stability for bigger or standing action figures.
- Installation of articulated joints to make poseable figures flexible and still durable.
In manufacturing where many parts are produced, equipment can place them and secure their joints to maintain speed and accuracy. Even so, premium figures often have to be put together by hand to achieve top quality. So, every figure keeps its planned appearance and functions before going further in the manufacturing process.
7. Painting and Finishing
After everything is put together, painting the figures comes next. Now, the figure comes to life as plain PVC is turned into a colorful, detailed version.
Painting techniques are:
- Airbrush is best for covering large parts of your body such as your skin and clothes.
- Painting eyes or logos can be done with a hand-painting process
- Printing using Tampo for intricate and detailed designs
- Water decals are suitable for complex or layered printing jobs.
You can make a product reflective, shiny or matte by choosing the correct finish. Coatings are sometimes applied to improve durability and its resistance to UV rays.
8. Quality Control
All figures are tested for quality before they are put into their final packaging. A top injection molding factory will ensure there are many places where quality control checks are done.
QC tasks can consist of:
- Checking the length, width, and height between figure features
- Looking for any marks, color problems or mold defects
- Keeping the joints or moving parts working as they should
- Checking the condition of the packaging and its labels
Any product failing the quality checks is either repaired or scrapped so that the same level of quality is maintained.
9. Packaging
The next step is to package the figure. When you package a figure, you can protect it, show it in an appealing way and include branding or instructions.
Packaging may consist of:
- Window boxes as a decoration
- Plastic bags that contain action figures
- Printed leaflets that explain how to use the product
- Green options are available to companies looking for sustainability.
Sometimes, figures issued in a limited edition get packaging or boxes made especially for collectors, making them seem more valuable to buyers.
PVC Injection Molding: Temperature & Pressure Ranges
| Factor | Typical Range |
| PVC Melt Temperature | 160–210°C (320–410°F) |
| Mold Temperature | 30–60°C (86–140°F) |
| Injection Pressure | 700–1400 bar (10,000–20,000 psi) |
The Importance of Choosing the Right Manufacturing Partner
Picking the proper injection molding partner is essential for figure production. Having a reliable manufacturing partner means you get molds that are detailed, accurate and they supply products with safe and durable materials. Fast production, the ability to scale and low costs are crucial as you go from the prototype to making many products. A factory that covers PVC injection molding, assembly and packaging all in one place avoids delays and reduces mistakes.
Professional manufacturers have experience sharing their knowledge in mold design and prototyping which benefits both the looks and usability of your product. Trusted partnerships over the years with factories allow brands to ensure quality, supply to the market and maintain their good reputation. The process of making a product successful and ready for buyers is made possible when a creative idea joins with the right manufacturing partner.
With these systems in place, top-tier factories report a 98.5% pass rate on final product inspections.
Final Thoughts
Creating a figure can be difficult, but it’s very satisfying. Design, digital sculpting, making molds and final packaging are all important parts of producing a high-quality product.
With improvements in PVC injection molding and the skills of current injection molding companies, tasks that once required months can be finished in a much shorter time, preserving both detail and strength.
Whether you’re in the toy business, an artist or a brand, being aware of this process allows you to plan better and achieve your goals.
