R2-D2 action figure

Series production requires a development process in which more skills and technologies converge, as in the case of the creation of the 3D model of the R2-D2 action figure, one of the most iconic characters in the Star Wars galaxy.

The assignment was commissioned by Maikii, the leading brand of licensed merchandising, and was divided into the following steps:

• analysis of the “artistic” 3D model sent by Maikii;
• optimisation of the initial 3D model;
• engineering of the 3D model, breaking down the parts and generating the mathematical formulas for injection printing;
• creation of the final prototype in a 1:1 scale (made in 3D printing)

Translating an “artistic” 3D model into a “technical” 3D model is a task that requires seamless collaboration between the artistic director and the designer in charge of redesigning every detail, taking into account the constraints of the specific technology used for the mould. Even the smallest variation of a detail can substantially affect the general figure. This aspect becomes critical in the case of models based on famous characters, universally recognised by the public.

In addition to being the essence of product modelling, 3D technologies play a key role in verifications. On the one hand, rendering allows designers to have a very quick pre-assessment of the details during the modelling phases. On the other, the physical prototypes, made in 3D printing, give the real perception of the details in a 1:1 scale. This is fundamental to validate the model and minimise the likelihood of errors in the final moulds. A considerable saving in time and general project costs.

R2-D2 Action Figure – 3D model with a proposed subdivision of the parts intended for injection moulding (credit: Protocube Reply)

R2-D2 Action Figure – final prototype, made in 3D printing (credit: Protocube Reply)