Have you or your li’l one ever wondered how toys are made? You’ve come to the right place!
Toy creation is a fascinating line of work. From sketching ideas to putting the fuzz on your favorite Li’l Woodzeez, each step is just as important as the last. And, in the end, we get something fun to play with! At Li’l Woodzeez, it’s our team’s job to turn simple ideas into figurines you’ll always love.
In this post, we’ll go over the steps on how to make figurines. For more behind-the-scenes looks at Honeysuckle Hollow, check out our interview with the Li’l Woodzeez toy designer!
Step 1: Brainstorming & Ideation
Every toy’s journey begins as an idea. Before a Li’l Woodzeez figurine can be held in your hands, our toy designer needs to decide which animal species they’re going to be and what they might look like within the world of Honeysuckle Hollow.
She asks herself questions like, “sloths or alligators?” “Penguins or bears?” Then, our designer does a little research to decide which animal should come out next. Part of her decision-making depends on what kids are loving, what would work well as a Li’l Woodzeez figurine, and what would make an adorable addition to the village of Honeysuckle Hollow!
Step Two: Sketching
Next is sketching! The second step in figurine manufacturing is putting all those fun ideas on paper. First, our toy designer draws Li’l Woodzeez with paper and pencil, then she draws them digitally on a computer tablet. There, she includes dimensions so that the factory’s engineers know exactly how big the figurines will be, including each feature.
While working on her tablet, our designer selects the perfect colors for the animals’ clothing and fur. They’ve gotta stand out! She also makes sure that those combinations of colors and patterns represent each of the characters’ personalities. Suzy and Tommy Tippytail, for example, are teachers. So, they’re dressed to stand in front of the class!
There is a lot of trial and error throughout this process. Not only does our designer want to make cute figurines, but also to stay true to the chosen animal’s features—like big, bushy squirrel tails or spiky porcupine quills! In the end, she draws the Famileez many times before landing on the perfect sketch!
Step 3: 3D Printing
At this point in the toy making process, our Li’l Woodzeez engineers create 3-dimensional models of our designs. Using advanced computer software, they bring the characters to life. Or almost!
So, those tails that were flat on paper become bushy and rounded. They also become jointed, so they fit into the squirrels’ backs. Every arm, leg, tail, head, and torso is made to fit perfectly, like pieces of a puzzle.
Once the 3D designs are complete, the engineers use a 3D printer to make what we call hand samples. That’s because they can be held in your hands! With hand samples, our designer can review the characters she created from top to bottom and make improvements. Maybe a snout looks too short, or a pair of ears is a little too rounded. In any case, this step is where the fun really begins!
Step 4: The Factory Makes Molds
With 3D Li’l Woodzeez figurines ready to go, the factory makes molds. Molds allow the factory to produce lots and lots of figurines at a much faster pace than with a 3D printer.
To make figurine molds, the factory takes a 3D-printed prototype (or hand sample) of a Li’l Woodzeez character and surrounds it with soft plastic. Once the plastic has set, the mold is opened up like a sandwich and the character is removed. This process is used for each piece of the animal figurine: the head, the body, the legs, and the arms!
With molds in hand, the factory can begin production. Known as injection molding, plastic is put inside the molds where the prototypes used to be. Then, machines press the mold together until the plastic hardens. And, voilà! A Li’l Woodzeez character is born.
Step 5: Painting
Now to put everything together!
At this point in the toy making process, everything is put together on an assembly line! The Li’l Woodzeez’s head, arms, and legs are put together carefully, then they are sprayed with paint. The colors and patterns all depend on their design. Pandas, for example, have black on their eyes, ears, arms, and legs! Some parts are painted by hand, too, to get the animals’ little eyes and noses just right!
Step 6: Flocking
Some Li’l Woodzeez figurines are fuzzy to the touch. That iconic texture is known as flocking!
To get that velvety-soft feel, the figurine is coated with special glue. Then, tiny fibers are added to its surface using electrostatic energy. (Crazy, right?) Those little fibers are charged so that they land upright on the Li’l Woodzeez body. Using a special machine, the fibers are added to the figurine and stick up straight, creating an even, fuzzy surface.
Step 7: Clothing
Another fun part!
While the Li’l Woodzeez figurines are being molded and painted, another team member makes our friendly critters’ clothes. Just like regular clothing, these outfits are cut and sewn and put together as if they were made for miniature people!
Every outfit is designed with that particular character in mind. If they like flowers, they might sport a flowery print. The Bogglesby Alligators, for example, wear aquatic-themed outfits because they love to swim!
Once both the figurine and its clothing are ready, the Li’l Woodzeez character gets dressed.
Step 8: Safety Testing
Testing, testing!
It’s important that all toys be tested for safety before li’l kids get their hands on them. no matter how toys are made. At this phase, the figurines are checked for defects, loose parts, and anything that might fall apart during playtime. This can not only prevent injury but ensure that playtime is both safe and fun!
Step 9: Packaging
Once safety tested, our Li’l Woodzeez figurines are put into their shelf-ready packaging. If they’re a family of four, they have a storybook included as well! This box is carefully designed by our art and design teams to make our figurines look their best. Each member of the family is strapped in so they stay together on their voyage to their future playroom.
Step 10: Shipping & Receiving
Bon voyage!
Finally, your Li’l Woodzeez friends are shipped to a toy store near you! Packaged and safety-tested figurines are put into boxes and travel by plane, train, and automobile to reach kids around the world. The toy making process ends when a store clerk puts a box of Li’l Woodzeez on the shelf for you to find and enjoy.
From start to finish, Li’l Woodzeez toys are made with tender, loving care. Making figurines is a complicated process that takes a team of experts who—at the heart of it all—love toys. Together, we make beautiful toys for kids and grown-ups to enjoy for many years to come.
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Let us know in the comments below which Li’l Woodzeez are your favorite, and which part of the toy making process you’d want to do most!
