Android mini production – Part 4: Molds and Pulls

Hello again everyone! The behind the scenes look continues, and now we’re getting to the messy bits!

Multiple copies of the a metal molds are created from the original master mold.

These molds are then attached to a frame built specifically for a roto-casting (aka rotational casting) machine. These particular frames pictured hold 12 android body molds. Hot liquid vinyl is poured into each form on the frame.

The molds are then capped off and inserted into a large roto-casting machine. This machine is essentially a large oven that spins the molds around in different directions while they bake. By spinning the molds we can ensure that the liquid vinyl coats all of the inside surfaces of the molds evenly and fully. Rotocasting also requires far less material than solid molding, and results in a lighter and more flexible product.

After a quick cool-down, the raw forms are still warm and soft enough to easily be pulled out of their molds. The excess material around the seams is trimmed off.

Sometimes the figures will become somewhat warped when they are pulled out of the molds. A quick trip to a heating rack makes them pop back into their original heat-formed shape.

Arms and antennae are too small and precise to be rotationally molded, those are created by a process called injection molding. Here the material is injected under extreme heat and pressure into a two part mold made from a solid aluminum block. Here you can see half the antennae on the left and half an arm on the right. That “gunk” you see helps lubricate the mold and ensure a good solid seal between the two parts.

Next Time: Painting pretty colors!

Android mini production – Part 3: Sculpting and Packaging

Time to move on to the physical production stage! With the reference design finalized, we start on a sculpt. Sometimes I’ll work out a rough in clay myself, but given the precise and geometric nature of this project I decided to leave it to an expert! Prototypes are typically 5-8% larger than the target production size to compensate for the shrinking that occurs due to mold production and material cooling.

A few revisions later and we’re getting pretty close. I went back and forth with the sculptor a few times annotating photos of the prototype in order to get the arms, legs and antennae just right.

Once the sculpt is finalized, a copy of the prototype body is cast in wax for final clean-up and mold creation. The body will be made of rotational-cast vinyl and the wax will be melted out when the mold is formed (molds pics in next update!).

Work on the packaging starts during figure production so that everything can be ready to go at once! Here is an individual box layout, nothing too exciting to see here but it is kind of neat to see it all flat.

A separate layer in the artwork file denotes areas that are to get a hit of glossy clear coating. This makes the boxes eye catching and also gives them a nice physical texture when you hold them.

Each figure is wrapped in an individual foil bag. This helps protect the figure from scuffing, but it also helps prevent tampering with blind-boxes. Originally the Androids had this neat printed pattern on their foil bags. Unfortunately the bag printer had just switched ink suppliers and hadn’t fully tested the new inks with the foil. Opening a few boxes led to little flakes of black paint all over your fingers, table and clothing, not good! At the last minute I had to ditch the printed bags and go back to plain old “ooohh shiny!”.  I think a few of these printed bags may have slipped through into the final production cases, consider yourself lucky if you found one, and go wash your hands.

Next Installment: Molds, hot vinyl!

Android mini production – Part 2: design layout

Hello again everyone! Last time we were laying the groundwork for the project to move forward, now the real fun begins as a final figure is fleshed out.

Once we had settled on the basic design, I created this line art “turnaround” reference. This layout includes basic scale measurements and detail notations for the sculptor as well as joint notations for the factory. It was also the first time I was able to show the rest of the guys working on the project exactly what I had in mind from all angles… which meant this was the first time that they had seen their mascot with my “fat” legs design.

This naturally lead to a discussion on the best way to create a compelling figure while staying as true to form as possible. Using brand-accurate rounded cylindrical legs would pose a problem, our little Android wouldn’t be able to stand up on his own! Being an avid collector myself, figures flopping over and taking Olympic caliber Shelf Dives is one of my pet peeves. The collector in me also knew that a stand is usually just an extraneous piece of plastic bound to be lost or broken. So I presented the team with a number of options including the above “fat” leg, which is brand-accurate from the front and at an angle, but not from the side; a short-round leg which was cylindrical, but had to be comically short to maintain a low center of gravity; and thin semi-rounded legs that could be longer, but would need to be angled to create a more stable triangular base.

Here is the final template, you can see which legs won in the end! I am still confident that this was the best balance of brand accuracy and real-world practicality. You can see on the lower right an area marked “Pantone reference”. For those unfamiliar with design in general, Pantone is an industry standard color reference guide. On-screen colors are often quite different from physical paint colors, so it is important to have an agreed-upon color goal. Typically a designer will have a book of color swatches and a factory will have the same book along with a formula guide to reproduce that exact color in paint.

Ok, maybe NOW the real fun has started. Designs are roughed out, refined and placed into the standard layout template. Here’s an edition of Creature Android that was a little too busy, we dropped the cityscape and the flames, but most of the design remained intact through the final round. Some other designs weren’t so lucky…

This guy never made it past revision 1. With plenty of design ideas around and a limited number we could produce, it was important to balance variety, novelty and fun. There were some good designs that hit the Series 1 cutting room floor, but hopefully we’ll be able to revisit a few of those in the future!

Next Installment: Sculpting, packaging.

Android mini production – Part 1: groundwork

While we all sit quietly and wait patiently for the next shipment of Android Series 1 mini figures to arrive, I thought I would entertain / inform you with a series of posts chronicling the creation of these little guys from start to finish!

It all started with this logo and a couple of designers working on the Android platform. Like many designers these days, they had become fans of the growing genre of limited edition vinyl figures created by artists specifically for an art-collecting adult audience. With a great mascot, a love of all things collectible, and a desire to do something cool, they set about to bring their idea to life.

Luckily another friend of theirs at Android happened to know someone with experience in vinyl collectible production, which is where I came in!

At the end of 2008 we started talking about the best way to go from logo to collectible. Could we adjust Android to an existing platform? Should we do a large expensive collectible? Can they all have different heads? Would a mini series be cool? Is blind box a fun format for tech centric people who may not be as familiar with the concept as traditional toy collectors? During the course of our discussions I threw together this mock-up of what a figure of the logo could actually look like.

It seemed that we were heading in the right direction with a multiple design mini series. I quickly created a set of simple concepts to illustrate that a series would give us the opportunity to create a variety of designs and showcase the versatility of their deceptively simple mascot. Even though these were early concepts, you can see that a few of the ideas and design elements made it all the way to the final products. Some designs (such as BSOD-BOT shown here) were scrapped for pretty obvious PR / legal reasons. Still, it was worth a shot!

With the concept hammered out and an OK from the big Android himself Andy Rubin, the project was a go! We were all set to create a mini series with a relatively small budget for a small quantity of figures destined for internal promotions and giveaways. Yes, originally these guys were not necessarily going to find their way into the hands of fans and collectors (and some of you would argue that they still haven’t!). This was shaping up to be a fun project, and I knew it would have some appeal in the world at large, although how much appeal was hard to judge. Selling collectibles based on mobile operating systems was an untested market to say the least. Thanks to the enthusiasm (and legal wrangling) of the guys at Android, we were able to work out a deal wherein I could produce a few more units to be sold directly to fans and shops.

Next Installment: Getting down to business on design.

Android mini collectibles in shops

Android toys are finally hitting a few select toy retailers. Here is a short list to get you started on your quest:

Illinois
rotofugi *

Ohio
rivet *

New York
my plastic heart *
toytokyo *
frozen empire

California
3d retro

cardboard spaceship
dragatomi
ningyoushi
Neon Monster *

United Kingdom

playlounge *
Tokyo Toy Store

*denoted that store also has a physical location.

Some shops have already gone through their stock, but others haven’t put them online yet. Some shops keep a few sets for their retail storefronts. Hint: newsletter subscribers got this information first!

More coming this summer if you miss out on these, including at the 2010 International Comic-Con!

Meet the Androids: Albino and APK 2008

Reminder: Do not go wasting your cash on eBay resellers with jacked-up prices, there will be more Androids in the future if you are patient!


People are starting to get their Androids! If you have some good photos why not drop them into our Flickr Pool?

One last “regular” Android to show off, followed by one of the rarer chase editions.. so don’t scroll down if you don’t want spoilers!

Name: Albino
ID: 09
Ratio: 1/16

High gloss white finish with red eyes.

— Yarr, below there be spoilers! —

Name: APK 2008
ID: 11
Ratio: ?/??

Someone had requested an explaination of this guy. Most Android devs and quite a few users will be familiar with APK, the file format for Android install packages. 2008 is the year Android debuted. The whole thing? An pretty blatant homage to one of my favorite classic Sci-Fi movies!

Release the Robots! *SOLD OUT*

What a crazy rush! Unfortunately we are now super extra sold out of our online stock. We had hoped to offer more this evening, but a software issue caused some over-sales.

If you missed out today, check back here in a week or two for a list of stores that will have some! If you miss those, there should be more available in a few months when our second shipment comes in! FEAR NOT, Androids shall be yours!

Meet the Androids: Worker & Octopoid

A two-for Tuesday! Excited about tomorrow? I know the one lady who will be shipping all of these orders is! Perhaps I am confusing “excited” with “terrified”.

In case you’re wondering when the figures will be available tomorrow, it will be a random time, and I will be adding stock throughout the day to give people in different time zones a chance! Don’t forget that a few cases of these will also be hitting select retailers in a couple of weeks. So if you miss out here, all hope is not lost.

Name: Worker
ID: 07
Ratio: 1/16

Will work for recharge.

Name: Octopoid
ID: 08
Ratio: 1/16

He’s all legs and suckers.

Meet the Androids: CopperBot & Reactor

Two for one mega-size Friday update! This is perhaps the most anticipated of the Androids teased so far. Say hello to my little friend, CopperBot.

Name: CopperBot
ID: 04
Ratio: 2/16

Metallic copper finish with mechanical detailing and an overwhelming desire to be loved.

Name: Reactor
ID: 06
Ratio: 1/16

You could even say it glows! (it does, in the dark)

Finally on another note, I will be at myplasticheart in NYC for a bit tonight to attend the opening reception for New Moon 2010! If you enjoy toys and art and are in the New York area, why not stop in?

Have a great weekend everyone!

Meet the Androids: Darknet

We continue our introduction to the designs! Half-way through working on this post the power went out in my building. Coincidence? Most definitely. This guy is named “Darknet”, not “Blackout”. He features black on black artwork and a crazy look in his red eyes.

ID: 05
Name: Darknet
Ratio: 2/16

I almost forgot to mention that O-No Sushi (red) won 2009 Toy of the Year over at the Plastic and Plush blog! I also managed to place 2nd in the artist category. I think someone might have a crush on ,e

Meet the Androids: Hi-Voltage

I’ll be taking the opportunity over the next few days to introduce some of the designs and share some more information!

As some of you have figured out, these guys will be available February 10th. The first batch will hit right here online (yes we ship internationally), followed in a week or two by a limited release in toy and collectible shops both online and in the real world! After that I’m afraid you’ll be waiting a few months while our replication pods recharge, so good luck! Price? About $7.25 per box, with discounts on cases of 16.

We’ve already seen standard Android, so today we start up with this electrifying Android.

ID: 02
Name: Hi-Voltage
Ratio: 2/16

Warning: Do not attempt to plug in.

Android mini collectibles

New from artist Andrew Bell and Google’s Android™ platform comes Android mini collectibles series 01!

Andrew, an avid Android user himself, teamed up with some friends at Google to bring their little green mascot to life. Series 1 features 12 different designs in blind-boxed cases of 16. Pick up a few and try your luck, or grab a whole case to secure a nearly-full set. Be on the lookout for some super rare chase editions. Each vinyl figure stands 3” tall and features a rotating head and arms.

Check back throughout the next few weeks for more photos and info!

Series 1 will be available later this month right here in an online Android collectibles shop and in specialty retailers. For wholesale inquiries contact DKE distribution.

Android™, related logo and character design are trademark Google Inc. and are used under license.

O-No Sushi giveaway via NOTCOT

Our friends at NOTCOT have a pre-release Green edition O-No Sushi figure to give away as a holiday promotion! Head on over there to check out the details!

http://www.notcot.com/gift-guide-2009/holiday_feature_o-no_sushi_figure_giveaway.php

You will also be pleased to know that the new shipment is IN and that your favorite stores will once again have Red O-No Sushi figures starting this week! Green on the way in January!

On the boat…

Word from the factory is that there is more sushi on the way! Better late than never, these guys should be back in stock online and in stores starting early December!