Designing a new Transformer is very involved. With Beast Machines, I work very closely with our Intellectual Properties (IP) group that is responsible for the animated series. It’s my job to brainstorm and introduce new and exciting characters and aesthetics that will not only mesh with the IP strategies, but also make great toys that will interest both kids and collectors.

        When the direction for a character is decided upon, then it’s up to me to design its look and transformation process.  I begin doing sketches of both the animal/vehicle mode and the robot from the Transformer becomes. When I have something I’m happy with, I scan in my drawings and tighten them up, adding colors and callouts in Adobe Photoshop. At times I’ll even kitbash a model (the process of taking parts from model kits and other toys and “bashing” them together to create a 3D model that will help get my ideas across).  These are then presented to my upper management, and given the go or no-go.  If they don’t like it, its back to the drawing board for me. Otherwise, I’m off and running.

        Then Takara (a Japanese toy company partnered with Hasbro since the early ‘80’s) makes a hard copy of my idea. From my concept drawings, they’ll create rough models showing the aesthetics for the toy and the transformation process they have in mind. This is where the process can get tedious. Good communication is a must. They constantly bombard me with j-peg images of the models, and I ensure their designs compliment the character’s direction and my own vision. I must say that those guys at Takara are amazing. They are true experts when it comes to outstanding details and the mechanics of a great Transformation process.

        After three to four months, I get a one-of-a-kind hardcopy prototype model of the Transformer -- the model from which all other duplicates will be produced. What a great feeling! Hardcopies are very hard to come by; that’s what makes them so rare and highly sought after by collectors. I usually receive 8-10 prototypes to test tolerances, fit, molded colors, etc. When I am finished, they are taken to the plastic grinder to be shredded. The reason for this is quality assurance issues. If a child got a hold of a prototype -- which is never cleared for the consumer -- and got hurt on a loose or broken piece by swallowing it, eating loose paint or what not, Hasbro could be sued. 

        The next step in the process is to create a mold breakdown of all the parts, and do a preliminary color breakdown of the decoration. After a few weeks, the duplicates are prepared and get painted by a support team per my specifications.

        After this six-month ordeal, I venture to the sign-off table in the sample department where I, my manager, and the rest of my team, will give the toy its final blessing. Then for another six months it’s off to the Far East where the actual manufacturing process happens. Phew!

        This is actually a small part of my job responsibilities at Hasbro, and not the only line I work on, but I must say it is the most satisfying and fun! Thanks to Derrick for giving me the opportunity to share a little about my job. Transformers Collectors ROCK!

        Prototypes develop in four to five different phases. The hardcopy (from which the tools are made) and the internal duplicates are fabricated to be decoed. This tooling hardcopy, from which the orient tools are actually cut, is also laid up in rubber molds to create internal samples. The samples are duplicated only on an “as needed” basis. Usually there is one that remains unpainted to be kept for reference and to help determine package structure. The rest (around 10-15) are used as decomasters to be hand painted by an internal support group for orient deco reference, package and cross-sell photography, and for use in television commercials. These are the hardest to come by and, according to some sources, the most illegal to own, buy or sell. Tooled prototypes, however, do slip into the hands of a few collectors who are lucky enough to find them.

        From cut-steel molds fabricated in the Orient, the first shots that are received, called first EP’s (Engineering Pilots) may or may not be assembled and in good working order, and most of the time are in haphazard resin colors. Second EP’s, the third type of protos, are usually closer to the final colors that will appear in the toy (the colors are usually tweaked at this point), and these seldom have any paint. Fourth are FEP’s (Final EP’s), which are decoed and reviewed to give the final say as to molded colors, decoration, and engineering concerns (these shots look very similar to a production piece that has been removed from the packaging). Finally come VSP’s (Vendor Sample Pilots), vendor samples that get final approval before mass production begins. This prototype is discerned by a green 3x5 Hasbro Standard tag taped to the back of the package.

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