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Assembly in Toy Manufacturing: The Final and Critical Stage for Action Figures

In the toy manufacturing process, assembly is the final stage and is crucial for crafting action figures to ensure they reflect the quality of the finished product accurately.

The basic workflow for toy product assembly includes the following steps:

Pre-Assembly Inspection: Initially, inspect all necessary product components, which include various parts and production materials, to ensure they meet quality standards.

Assembly Process: Begin assembly according to the operational guidelines provided.

Product Testing: Conduct tests on the assembled products. If a product fails to meet the standards, perform a repairability analysis and handle accordingly—products that are fixable are retested post-repair, and those that cannot be repaired are dismantled and disposed of properly.

Cleaning and Finishing: Once a product passes all tests, it undergoes dust removal processes such as wiping and blowing.

Packaging: The product is then packaged using methods like sealing in plastic bags, thermoforming, or placing in color boxes, depending on the requirements.

Shipping Preparation: Finally, products are boxed as per shipping standards set by clients, inspected to ensure compliance, and then formally stocked in the warehouse.

This sequence not only ensures each toy’s functionality and aesthetics but also adheres to rigorous standards for quality assurance throughout the production cycle.

How To Custom Made Your Action Figure Toys?

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What Materials are Used in Designer Toys?

PVC (Polyvinyl Chloride)

This material is the most common in designer toys, with many blind box products made from PVC. It features a smooth texture, solid weight, capable of showcasing very small details, and excellent paint finishing. Examples include toys from Pop Mart.

Vinyl

Vinyl is actually a technique rather than a material, categorized into soft vinyl and hard vinyl.

Soft vinyl designer toys are typically molded at high temperatures, resulting in a soft and delicate texture. They are colored and shaped, but pressing hard can cause slight depressions on the surface.

Hard vinyl pieces are lighter and often hollow. They have sharp edges, vibrant colors, rich color layers, delicate textures, and are favored for their ease of disassembly and assembly, often chosen for larger dolls with many accessories.

Resin

Resin toys are heavier and can be transparent or opaque solid pieces. They offer high precision, clear edges, low wear and tear, rich colors, and varied shapes. However, they are prone to breakage when carried, despite being a highly utilized material in designer toys.

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The origin of art toys

Everyone has their own small world of toys.

In the process of human evolution, the tools that were repeatedly played with and gradually used should be the earliest forms of toys. It can be said that toys have served as experiments for human intellect and development.

In 2016, the global toy market reached an import and export scale of $78.7 billion, with over 43% comprising educational toys suitable for a wide age range, extending up to 80 years old. So, don't just play — let's delve deeper into understanding.

In the future, plastic products will surround humanity like air, becoming commonplace.

Libuše Niklová, a renowned Czech toy designer from the 1960s and 1970s, once said: "In the future, plastic products will surround humanity like air, becoming commonplace. Meanwhile, natural materials will increasingly resemble luxury items, objects of envy for people. Regardless, tomorrow belongs to plastic."

In the history of product design in the 20th century, her designed toys left a profound impact on a generation.

From the 1950s, Niklová began experimenting with plastic to create her series of whimsical and brightly colored characters and animals.

Her son, Peter, was fortunate to be the first player of these toys. He would play with every new item his mother brought home, and Niklová would refine her products based on his reactions.

In 1963, she pioneered the use of molded rubber, which featured a squeaking sound.

Some ask whether toys have already become a part of art. Certain art derivatives even circulate back into professional art auction markets, significantly increasing their collectible value. This trend also offers collectors more imaginative space, allowing more collectors to affordably own their own pieces. In this era, every circle is merging and evolving continuously.

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Types of vinyl toys

Vinyl toys come in a wide variety of styles and designs. Here are some common types of vinyl toys:

Designer Toys: These are artist-designed vinyl toys that often feature unique and creative designs. They are highly collectible and can range from abstract shapes to characters inspired by pop culture.

Urban Vinyl Toys: Also known as urban vinyl figures, these toys often depict characters from urban culture, street art, or graffiti. They can have a more edgy and contemporary aesthetic.

Pop Culture Vinyl Toys: These are vinyl toys that are based on popular characters from movies, anime, TV shows, comics, or video games. They often have licensed designs and appeal to fans of specific franchises.

DIY Vinyl Toys: These toys come in blank or unpainted forms, allowing collectors or artists to customize and personalize them with their own designs. They are popular among artists and enthusiasts who enjoy customizing toys.

Mini Figures: These are small vinyl toys that are typically around 2-4 inches tall. They come in various styles and themes and are often sold in blind box packaging, adding an element of surprise to the collecting experience.

Sofubi: Sofubi is a term used for soft vinyl toys that originated in Japan. These toys often have a distinct Japanese aesthetic and can range from cute and whimsical characters to more detailed and realistic designs.

These are just a few examples, and the world of vinyl toys is constantly evolving with new styles and designs being introduced by artists and manufacturers.

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Differences Between vinyl and Plastic

1. Material Composition:

vinyl and plastic are two different types of materials. vinyl is a polymer material composed of rubber, resin, fillers, and other components, known for its flexibility and ability to be molded into various shapes. Plastic, on the other hand, refers to a category of materials primarily composed of synthetic resins processed into shapes using various methods. In terms of material, vinyl is relatively more elastic, while plastic tends to be harder and more brittle.

2. Texture Differences:

Due to their different compositions, vinyl and plastic also differ in texture. vinyl has a soft, smooth, and flexible texture, providing a comfortable feel with a somewhat plush quality. In contrast, plastic has a harder, smoother surface texture, often feeling cooler and more rigid to the touch.

3. Usage Differences:

Furthermore, vinyl and plastic have significantly different applications. vinyl is widely used in various industries such as rubber products, steel products, automotive, textiles, aerospace, construction, and healthcare. Examples include tires, seals, belts, hoses, shock absorbers, vibration dampeners in the rubber industry; and gaskets, brake pads, interior trim, bundling tools, and railway track pads in the railway and automotive industries. Plastic, on the other hand, is primarily used in everyday products like plastic goods, bags, cling film, plastic toys, furniture, and more.

In summary, while vinyl and plastic are both polymer materials, they differ greatly in material composition, texture, and application. The choice between vinyl and plastic should be based on specific requirements and applications.

[xiaoxiaopuff]

The origin of art toys

Everyone has their own small world of toys.

In the process of human evolution, the tools that were repeatedly played with and gradually used should be the earliest forms of toys. It can be said that toys have served as experiments for human intellect and development.

In 2016, the global toy market reached an import and export scale of $78.7 billion, with over 43% comprising educational toys suitable for a wide age range, extending up to 80 years old. So, don't just play — let's delve deeper into understanding.

In the future, plastic products will surround humanity like air, becoming commonplace.

Libuše Niklová, a renowned Czech toy designer from the 1960s and 1970s, once said: "In the future, plastic products will surround humanity like air, becoming commonplace. Meanwhile, natural materials will increasingly resemble luxury items, objects of envy for people. Regardless, tomorrow belongs to plastic."

In the history of product design in the 20th century, her designed toys left a profound impact on a generation.

From the 1950s, Niklová began experimenting with plastic to create her series of whimsical and brightly colored characters and animals.

Her son, Peter, was fortunate to be the first player of these toys. He would play with every new item his mother brought home, and Niklová would refine her products based on his reactions.

In 1963, she pioneered the use of molded rubber, which featured a squeaking sound.

Some ask whether toys have already become a part of art. Certain art derivatives even circulate back into professional art auction markets, significantly increasing their collectible value. This trend also offers collectors more imaginative space, allowing more collectors to affordably own their own pieces. In this era, every circle is merging and evolving continuously.

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Why not all trendy toys use PVC?

The main reason is a major issue with it—molds.

During the production process, PVC needs to be heated and melted before it can be injected into molds, which must be made of metal (such as steel or copper). However, metal molds are costly, so to spread out the expenses, production quantities must be increased. The larger the production volume, the lower the overall costs of materials and molds.

Blind boxes, often used for casual play, require large production volumes, making PVC the preferred choice due to its overall material performance and cost-effectiveness.

Another issue with PVC is the necessity of adding a large amount of plasticizers.

PVC is the only one among the major plastics that must use plasticizers, allowing it to be soft and elastic or hard and brittle. However, many of these plasticizers are harmful to human health, especially DEHP (Di(2-ethylhexyl) phthalate), which vaporizes easily at high temperatures and can dissolve into oily liquids, disrupting the endocrine system and potentially causing cancer after being inhaled.

Currently, several states in the EU and the United States have expressly prohibited the use of DEHP. Despite its hazardous nature, it remains the most widely used and produced plasticizer due to its favorable physical properties and low cost.

PVC itself is odorless; the pungent smell often noticed when opening blind boxes is from the plasticizers released by PVC.

PVC is the most common material used in trendy toys. Both vinyl and Sofubi toys use PVC. It is suitable for large-scale production due to its low material costs and higher mold expenses.

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Building Block Man

The earliest concept of building block man comes from children's assembly toys produced by the Danish (LEGO) LEGO company. Each square part is covered with protrusions of the same size, and the back is a hollow partition area. Multiple parts can be combined to form shapes. This way of playing was originally used to inspire children's intelligence, but in the hands of adults, many masters have used them to build many surprising works, and this "modern building block" has gradually been accepted by adults.

In the toys launched by LEGO later, there are no longer just single toy scene parts, but many characters that match the scene are added. The characters themselves are simple in shape, divided into heads, bodies, and limbs. Some characters also have accessories such as guns or hats. Due to their compact workmanship and mobility, this character was quickly independently developed by LEGO as a separate project and sold separately. This kind of little man is the earliest known as the building block man. Until 2000, some Japanese and Hong Kong designers took a fancy to this well-known toy shape and began to borrow its shape for artistic modification.

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How to Clean Vinyl Toys？

Vinyl toys, also known as soft vinyl toys, are often squishy and commonly include items such as rubber ducks and frogs. If vinyl toys become dirty due to surface dust, they can be cleaned by wiping with warm water mixed with detergent. They do not require specialized cleaning methods. However, if the toys discolor due to chemical reactions or oxidation, they cannot be cleaned.

Vinyl toys are comfortable to touch, smooth, and come in both soft and hard varieties. They are hollow inside. When first purchased, it is essential to wash them thoroughly with clean water, as vinyl material typically has a scent. It is best to allow the smell to dissipate before letting children play with the toys.

Suggested Cleaning Method for vinyl Toys:

1. Dissolve some bleach in water, soak the plastic toys in it, and scrub. After removing the dirt, rinse thoroughly with clean water. Dry the toys in a ventilated area and avoid direct sunlight to prevent deformation.

2. Plastic toys can also be disinfected with a chlorine-based disinfectant solution, such as an 84 disinfectant solution. Note that plastic toys should not be subjected to high temperatures as they may deform. The concentration for dilution should be between 0.2‰ and 0.5‰ (i.e., 2 to 5 ml of disinfectant per 1000 ml of water). Soak the toys for 10 to 30 minutes, ensuring they are fully submerged. After disinfection, rinse the toys thoroughly with clean water before use.

3. The disinfectant solution should be kept covered to ensure effectiveness, as chlorine is a volatile substance. Keep the disinfectant and toys out of reach of children to prevent accidental ingestion or handling.

Toys should be cleaned regularly, depending on how often they are used by children. At a minimum, toys should be washed once a month. Additionally, educate children not to chew on toys, to tidy them after playing, and to wash their hands before eating. This helps to protect your child effectively.

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POP MART

POPMART, a well-known domestic trendy retail brand, is under Beijing POPMART Cultural Creation Co., Ltd. It is a cultural entertainment enterprise that integrates artist discovery, IP incubation and operation, customer engagement, and promotion of toy culture. Over the past decade, POPMART has focused on four main areas: artist discovery, IP incubation and operation, customer engagement, and promotion and cultivation of toy culture. Its goal is to build a comprehensive operational approach covering the entire toy trend industry chain, aiming to "create trends and spread beauty."

To deepen communication with more young people who love trendy toys and promote the brand concept of "creating trends and spreading beauty," POP MART has successfully held five large-scale international toy exhibitions in Beijing and Shanghai. Each exhibition attracts over 100,000 visitors, filling the gap in China's toy industry. Through these exhibitions, POP MART encourages more international trendy toy brands to pay attention to the domestic market and provides opportunities for excellent Chinese designers to showcase their original art, thereby boosting the development of China's toy culture.

Currently, POP MART has established a brand advantage centered on designers, retail channels, and industry chains. It has signed contracts with trendy toy designers such as Kenny, Bikki, and Long Jiasheng, launching many popular trendy toy products that have built a strong and high-quality fan community. Additionally, POP MART collaborates with international brands to create trendy products loved by young customers for classic IP characters.

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Revealing the Secrets of Doll Materials

Common doll materials include plastic, resin, ceramic, and soft vinyl, each with its own characteristics and suitable applications.

1. Plastic

Plastic is one of the most common doll materials, typically made using injection molding. It is known for being cost-effective, high in production precision, and available in a wide range of colors. Plastic dolls are suitable for characters with intricate details and complex designs, such as mechas and robots.

2. Resin

Dolls made from resin can achieve various intricate designs. They are ideal for creating characters with noble and splendid appearances, such as goddesses and royalty. Resin dolls generally have a longer lifespan compared to other materials but can be relatively fragile.

3. Ceramic

Ceramic dolls are often handmade and very delicate. They are suitable for depicting traditional cultures, historical figures, and characters from martial arts dramas. Ceramic dolls are hard and durable, making them suitable for display purposes.

4. Soft Vinyl

Soft vinyl dolls are made from materials like silicone, offering a soft and realistic touch. They are known for their good articulation and interchangeability, making them suitable for creating characters from manga, anime, and games, appealing to model enthusiasts.

In conclusion, different doll materials are suitable for different scenarios, each with its own advantages and disadvantages. When choosing a doll, it's important to consider the intended use and select the material that best meets those needs.

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What are Trendy Toys?

In recent years, alongside the craze for "everything can be blind boxed," trendy toys have gradually entered the public eye. Also known as art toys or designer toys, trendy toys integrate concepts from art, design, trends, painting, sculpture, and more. They are primarily targeted at adults. According to reports, the development of trendy toys in China has been rapid, with the market size growing from 6.3 billion yuan in 2015 to 20.7 billion yuan in 2019. Many trendy toy companies have started to venture into overseas markets, and some Chinese designs have gained popularity among international consumers, demonstrating strong innovation and cultural influence. Trendy toys are no longer a niche hobby for a few; they have risen to become a form of spiritual consumption and a cultural phenomenon.

In physical stores, many prominent locations in large shopping malls are occupied by trendy toy shops and vending machines, where people enthusiastically spend tens of yuan to buy a "small moment of happiness." Online, domestic trendy toy brands like Pop Mart have surpassed LEGO and Bandai for two consecutive years, ranking first in the toy category sales list on Tmall's "Double Eleven" shopping festival. Additionally, some museums have also experimented with launching cultural and creative products in blind box formats, traditional stationery companies are exploring this market, and many internet companies are entering this industry...

This is a consumer frenzy among young people and an attempt to bring art closer to daily life at affordable prices.

Trendy Toys: A New Business Format Linking Art and Commerce

"In fact, trendy toys are a form of art peripherals, bridging the gap between art and toys." The current consensus in the industry is that trendy toys in a narrow sense originated in late 20th-century Hong Kong and Japan, created by independent designers and artists, also known as art toys or designer toys. These works often feature a hint of street culture, rebellion, and anti-mainstream style, produced in limited quantities and thus relatively expensive, initially appealing to a small circle of enthusiasts.

By the early 21st century, the concept of trendy toys fused with local anime, film, and television industries in Europe, the United States, and Japan, giving rise to globally renowned trendy toy brands and characters such as KAWS and BE@RBRICK.

After entering mainland China, trendy toys diversified in form and shifted their focus from being purely art or designer toys to targeting a larger market—the art peripherals market. More and more companies related to toys have entered the industry chain, forming a preliminary ecosystem for trendy toys from design, production, and sales to the secondary market and large-scale offline exhibitions.

Among them, large-scale offline exhibitions have become a window for quickly observing the trendy toy industry. Designers seize the opportunity to communicate and exchange ideas with peers, discovering new trends and changes in the industry. "You will find that this circle is experiencing iteration and integration. People are playing with things that are increasingly similar. Those who used to only collect statues are now also starting to play with trendy toys and figurines. Those who didn't play with statues before are now paying attention to them with the rise of trendy toys," says Zhu Jiaqi, Art Director of Kai Tian Studio, seeing this as a sign of the trendy toy industry gradually maturing.

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Gashapon

Gashapon, or capsule toys, originate from Japan. They consist of small toys enclosed in transparent spherical capsules.

You can often find self-service vending machines for gashapon at toy stores or convenience store entrances. By checking the promotional card on the machine, you can see which style of toy is available inside. Simply insert a coin (typically ¥0.5 or ¥1.0), twist the mechanism in front of the machine, and a capsule will drop from the bottom containing one of the illustrated styles, similar to a lottery feeling. However, some machines may specify "1:1 type" on their promotional cards, indicating that other types of toys at the same ratio are added, reducing the chances of getting the original style.

Collecting a complete set can be costly and may result in duplicates. Some toy stores sell complete sets, which is more convenient than buying individual gashapon and often available well in advance before they are put into gashapon machines.

A typical gashapon contains a plastic eggshell that can be opened into two halves, with a toy and an instruction sheet inside. The instruction sheet for gashapon is also known as "egg paper". Due to the size limit of gashapon shells, most toys inside require assembly, enhancing their playability. Egg paper serves as a promotional leaflet for gashapon; collectors should keep it as it holds commemorative and trading value.

To reduce transportation costs, wholesalers often remove the eggshells from gashapon, so most gashapon sold in stores do not include eggshells but do include egg paper.

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The Rise of Vinyl Figures

The game version of the Q-version CS Troopers, produced by Kawai Studio Inc., a subsidiary of the Japanese company GAMEITOY, is crafted by renowned Japanese manga artists based on the concept of 12-inch CS series action figures. These are globally limited to 1000 sets. In the Hong Kong movie "Love on a Diet" starring Andy and Sammi, the plump figures are particularly amusing. The figure's "body" is not a single piece but assembled from various "parts," allowing for limbs to be moved and posed at will.

Eric So, world-famous for his Bruce Lee figures, receives accolades for his uniquely styled and era-evocative Bruce Lee figures. His SoU14, Estate, and Masks figures have also gained widespread popularity. Meanwhile, Zhuaimao by Dongguan Manga Colors Culture Communication Co., Ltd. fully explores the exaggerated imagination associated with vinyl figures. Designed by the Manga Colors team, the American comic hero series showcases distinct and highly individual characters. Each Zhuaimao figure, despite being made of the same material, is remarkably unique, breaking away from the typical "replication" production model of toys.

Most customers are gamers, and they note that the vinyl figures are produced in limited quantities—ranging from a few dozen to a couple of thousand. This ensures their uniqueness, but with prices often ranging from hundreds to thousands of dollars, the market is not widespread. Unlike typical children's toys, these figures target a demographic with disposable income, inclined towards classic and collectible types. Items related to the Spanish Real Madrid star David Beckham, such as his number 23 jersey or a 12-inch Beckham vinyl figure, are also highly popular.

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Materials for Action Figure Production

Cast Resin

Commonly known as PU resin, Cast resin, specifically HEI-CAST resin from Japan, is a type of non-foaming polyurethane resin comprising two components (A and B) that must be mixed in equal weight ratios. Available in colors like white, off-white, and ivory (variations like 8012 off-white, 8014 white, 8017 ivory, including transparent and other specially mixed colors), Cast resin is lightweight and highly pliable. It is the best material for detailing and offers an exceptional feel similar to ivory when finely polished, making it the top choice for creating GK (Garage Kit) models. However, it is more expensive compared to other materials, costing around 300 RMB for a two-kilogram set (1kg each of A and B) as of 2020, with prices having decreased to around 100 RMB. Cast resin figures are relatively easy to process and are primarily used for original versions.

Japanese Edition Figures

The material of Japanese edition figures is usually labeled as "cold resin cast kit." 'Cold' refers to the cold molding process, which does not require the material to be heated before molding, unlike other plastics like PVC or ABS that must be melted. 'Resin' denotes the material, and 'kit' indicates that it is a set, so it translates to a cold-molded cast resin kit.

8012, 8014, 8017 Resins

These are common types of AB resin used frequently.

Polystone

A material made from a mixture of resin and stone powder, Polystone is a type of cold resin. It is much cheaper than cast resin, costing less than one-third, and is referred to as polystone in English. It was a primary material for early finished figures and is generally unsuitable for hobbyists making GK models due to its impact resistance, heat resistance, high hardness, heavy weight, poor plasticity, and propensity to break due to excessive hardness. Its color can be altered by adding color powders.

PVC (Polyvinyl Chloride)

Commonly known as soft vinyl in Western contexts. Unpainted soft vinyl components, unlike the first category, are made of a soft, rubber-like material that is much cheaper. The same model can be purchased for less money, and it offers greater flexibility for modifications than resin materials.

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What are the categories of figures?

Figurines come in many varieties, differentiated by materials, manufacturing techniques, size, and style. They can be categorized as follows:

1. GK (Garage Kit): These are resin model kits crafted by anime enthusiasts. Typically unpainted, they require the buyer to assemble and color them. GKs are known for their limited availability, high price, and superior craftsmanship, making them suitable for advanced collectors.

2. PF (PVC Figure): These are painted finished products made primarily from polyvinyl chloride (PVC), typically produced and sold by professional companies. PFs are characterized by their wide availability, moderate price, and average craftsmanship, making them suitable for general collectors.

3. SD (Super Deformed): These models feature characters with exaggerated proportions, usually with a much larger head compared to the body, and a cute expression. SDs vary in style and size, are affordable, and have lower production quality, appealing to collectors who favor a cute aesthetic.

4. RAH (Real Action Heroes): These are action figures scaled to 1/6 or 1/12 size that realistically replicate anime characters, often including fabric clothing and accessories. RAHs are known for their lifelike appearance, flexible articulation, high cost, and high quality, suited for collectors who appreciate realistic figures.

5. Nendoroid: Created by Good Smile Company, this series features SD-style figures with interchangeable expressions and accessories. Nendoroids are noted for their adorable design, expressive faces, reasonable pricing, and high quality, ideal for collectors who enjoy customizing their figures.

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The Magic of "OZAI" Blind Boxes

When it comes to blind box toys, many are familiar with Bubble Mart.

However, "OZAI" is a product under "Heyone" that launched its first generation of blind boxes in May 2022. The "OZAI" original vinyl blind boxes were recently released in multiple stores nationwide, with a global limit of 3,999 sets. Each person or ID was restricted to purchasing just two boxes, requiring them to queue at specified locations, receive a number card, and use it to make a purchase.

Unlike Pop Mart, "OZAI" toys are vinyl plush figures, which means they offer a different tactile and quality experience. Leveraging years of built-up popularity and appealing real-life images, these toys quickly became a hit.

In cities like Qingdao, Hangzhou, and Dalian, netizens posted that people began queuing in front of stores as early as the 14th to snag these items on the 15th... Searching on secondary platforms reveals that "OZAI" original vinyl blind boxes are often sold at a premium; standard models go for hundreds of yuan, while rare variants fetch prices in the thousands.

The limited release strategy of this emerging trend-setting brand translates to a form of "hunger marketing." The blind box approach inherently involves a taste of limited edition releases, but now this tactic is openly used to spark impulsive purchases among fans, artificially creating blockbusters that garner more attention than their intrinsic value might suggest. This reflects a marketing mindset where, despite the potential for high sales volumes, products are intentionally kept scarce.