Creating high-quality PVC action figures involves several key steps, from initial design to production using injection molding. By following this process, manufacturers can create detailed, durable action figures that meet market standards. This guide walks through each stage of development, using Demeng Toy's expertise in custom toy production as a reference.

Concept and Design

The process begins with a clear character design. Whether you're creating custom action figures or replicating existing characters, detailed sketches or 3D modeling of the figure’s appearance, including facial features, clothing, and pose, are essential. Using software like Blender or ZBrush, you can design the figure’s articulation points, ensuring the final product meets functional expectations

Prototype Development

Before moving to mold making, it’s critical to create a prototype sample. This physical model serves as a guide for the injection molding process and allows for testing and adjustments before mass production.

Hand-sculpted Prototypes: Some artists use polymer clay or epoxy to sculpt the figure by hand, capturing fine details such as facial expressions and costumes.

3D Printing: Alternatively, 3D printing offers precise, efficient prototype production based on your 3D model. It enables quick revisions and ensures all design elements are accurate before proceeding​.

Mold Making for Injection Molding

Once the prototype is finalized, the next step is creating the injection mold. Molds are typically crafted from high-strength steel and are used to shape the PVC material into the desired form.

Mold Design: The mold is designed to perfectly fit the figure's shape and is typically divided into two parts to allow for easy injection of molten PVC and removal of the solidified product.

Mold Creation: Using CNC machining or EDM (Electrical Discharge Machining), the steel mold is precisely cut to match the prototype’s shape. Cooling channels and vents are incorporated to ensure even cooling and prevent defects such as air bubbles​.

PVC Material and Injection Molding Process

With the mold ready, the PVC action figures are produced through injection molding.

Material Preparation: PVC pellets are melted and injected into the mold. This process allows for the replication of fine details and ensures the figure's durability. The temperature and pressure must be carefully controlled to ensure a high-quality finish​.

Injection Molding: The molten PVC is injected into the mold under high pressure, filling every cavity. Once cooled, the figure solidifies into its final shape. For precision, Demeng Toy employs advanced techniques to prevent imperfections such as warping​.

Assembly and Post-Processing

Once the parts are molded, they need to be assembled and refined:

Assembly: Depending on the figure’s design, various parts like the head, arms, and legs are assembled. Articulated joints are also installed at this stage to ensure the figure’s flexibility and durability​.

Finishing: After assembly, any excess material (such as flash) is trimmed, and the figure is polished to ensure a smooth, professional finish​.

Painting and Detailing

The painting process brings the action figure to life:

Priming and Painting: A layer of primer is applied to the PVC surface to ensure the paint adheres properly. Airbrushing and detailed brushwork are used to apply the figure’s colors, focusing on fine details like facial features and clothing patterns​.

Sealing: A clear coat is applied to protect the paint and add a professional finish, making the figure more durable and aesthetically appealing.

Quality Control and Packaging

Once the PVC action figures are completed, each unit undergoes strict quality control to ensure it meets design and durability standards. Factors such as joint articulation, paint quality, and overall appearance are evaluated.

Packaging: Figures are then carefully packaged in custom boxes or blister packs, ensuring they are ready for display or shipping without risk of damage​.