This is the third part of our first blog entry. We are sharing the process we went through to create two toy figures from our “The Offsiders” story. In the first post we started with a vector version of the characters. Then we polished them in Photoshop.  Now it´s time to move from the digital version of “Sergi” & “Svenson” into a tangible toys.

We knew we wanted to create more figures from the same line in the future. And also add a “do it yourself” component via swappable parts. So, for example, you could have Svenson” mixed with “Sergi” and create something new. This swappable component has to be in mind during the 3D process in order to create the right joints. In the previous post I mentioned that during this stage we had to go back and forth from Photoshop to Illustrator. This was mainly for two reasons.[/vc_column_text][/vc_column][/vc_row]


1) For being the first two figures created Sergi” & “Svenson” were too similar (anatomically speaking) with each other. This was a problem if we wanted to swap pieces between them. So we went back to Ai to edit Svenson’s” arms and notably differentiate them from “Sergi’s”.

We had second issue with the arms. We liked how “Sergi” looked in the illustration but once we had his toy figure in our hands we were not happy with the shape of his hands. They looked too small and couldn´t differentiate enough from the rest of his arms. So we threw them away and printed a new pair of arms, with bigger hands and wristbands.


2) Due to size limitations on the material available at that time to sculpt “Sergi” & “Svenson” we had a maximum width surface to work with. We used a pvc 60mm rod. We couldn’t go beyond that width. And both hair pieces were much wider than allowed. So we had to edit their hairstyles before starting the 3D modelling.


“Sergi” and “Svenson” were modeled using Rhino. I kept polishing the vector files incorporating the feedback Mat gave me since he has a better knowledge of 3D and materials. Some details had to be left behind and we had to center in the concept of parts being “universal” so you could swap them with others.



We chose pvc 60mm because it is great for machining. Some of its advantages are the smooth surfaces that can be obtained and its high impact resistance.

Machining is tricky too, it is very important to study in advance how to work on each piece, defining the way the material is hold on the machine can be a real pain in the neck. Vibrations, the drills used, the quality and shape of the material, etc. have a direct impact on the finishing of the piece.

In the image above you can see both toy figures ready. We still have to paint them. But that will be part of a future post.

Hope you enjoyed the process!