CLOSE
Hasbro
Hasbro

How Hasbro Created its 6-inch Jabba the Hutt Action Figure

Hasbro
Hasbro

When attendees line up outside Comic Con International for tonight’s preview, there’s one exclusive they’ll be probably more eager to get their hands on than any others: Jabba the Hutt, the first figure in Hasbro’s Star Wars Deluxe Black Series. The 6-inch action figure comes in a replica of the character’s throne room—complete with space for last year's SDCC exclusive, Han Solo in carbonite!—and includes Jabba’s hookah and his cackling sidekick, Salacious Crumb.

It was easy to choose which character would be the first to get the 6-inch treatment in the new Deluxe Black Series line. “Jabba’s sort of a no brainer for ‘deluxe,’” Sam Smith, Senior Product Designer of the Star Wars brand at Hasbro, says. “He’s such a quintessential Star Wars character and we knew he would be awesome at this scale.”

MAKING THE BLACK SERIES

Top: Photo reference for Jabba's Hookah. Bottom: Photo reference for the frog in Jabba's hookah.

No matter which character they’re making a figure of, the team always starts by gathering reference. Usually, that means amassing as many photos of the character and its accessories as possible to ensure film-level accuracy. “Many of the classic archival items are based on image turns rather than 3D scans or renderings [of puppets] since the costumes are delicate and, in most cases, require a person to be in them to capture the images,” Smith says. “Instead we refer back to the many on-set photos, film screen shots, and Lucasfilm-approved reproduction art. In some cases, there are so many images and pieces of reference out there that you start to notice subtle differences in features, accessories, etc. Here we work closely with Lucasfilm to ensure we are replicating the approved, on-canon elements.”

After determining how much articulation the figure will have and deciding on its features and accessories, all the information the team gathered goes to the sculptors, who develop a model. “This is a close partnership that consists of a lot of back and forth and attention to the small details,” Smith says. “We’ve also moved to a completely digital sculpt environment. In the past, we would go through a lot of wax stages, but everything created for Hasbro’s Star Wars Black Series has been done digitally, which makes the process more fluid.” During this period, the team is in constant contact with Lucasfilm for input and approvals at each stage of the figure’s development.

Top: An image of Jabba's sidekick, Salacious Crumb, from the movie. Bottom: Hasbro's 3D sculpt of the Crumb figure.

After the final digital sculpt is approved, the team develops a “tooling copy”—an initial prototype of what will hopefully be the final functioning action figure, and which serves as a blueprint for the final figure—with its Hong Kong-based factory. “During this stage, we are developing deco [i.e., paint, graphics, etc.] based on painstaking review of reference,” Smith says. Finer details, like a figure's eyes, are painted, while larger areas of the figure, like legs in pants, are molded in a certain color plastic, and details are applied in paint. Graphics are applied in a process called tampo printing; they’re tapped or pressed onto an item with a soft-tipped, automated arm/finger.

“When deco is approved and we have our final paint master model,” Smith says, “we then hand the model over to our factory to reproduce it in a consumer format.” The process consists of multiple rounds of reviews to ensure that the figure is an accurate replica of the approved model; Smith says that during this time, the team is evaluating the mold layout and colors, draft angles, deco application, soft goods application, and even the packaging layout. Once Hasbro and Lucasfilm have approved a pre-production sample from the actual line, they proceed with the final production.

Modern technology has made the whole process much easier than it was a few decades ago. “We have the advantage of being able to quickly obtain assets and concept art much earlier in the entertainment development stage,” Smith says. Instead of drawing sketches with pencils, designers use Cintiq drawing tablets, and concepts are vetted digitally instead of on physical boards. Wax and physical models have been replaced with digital modeling and 3D printing, which allows the team to “test out new concepts, new articulation, etc. and can make changes on the fly,” Smith says. “We can also rapidly deploy new concepts and get much faster approvals internally and with Lucasfilm. Gone are the days where we are left waiting for faxed input and approvals.”

JABBA’S CLOSEUP

Photo reference for Jabba the Hutt.

Besides his sheer awesomeness, there were a few other reasons why Hasbro chose Jabba to be its first 6-inch figure. “He’s big enough to work within the scale and create a commanding presence when placed alongside our other 6-inch figures, but he’s not too huge like a Rancor, which wouldn’t fit on shelf at your local retailer,” Smith says. “We also like that he allows the 6-inch line to break the typical humanoid form. Apart from R2-D2 all of our previous offerings have been bipeds.”

And because Tatooine's slug-like kingpin loves to chat about his palace and carbonite-encased conquests, the figure also provided the designers a fun opportunity for an action feature: When you push down on Jabba’s arm, his mouth moves. To pull it off, “his whole upper body needed to be sculpted from a softer rubber material,” Smith says. “We also installed geared linkage between his arm sockets and the mouth to get the effect. But this is Hasbro’s Star Wars Black Series, so it wasn’t enough to include this feature. We had to include it in a way that still allowed the arms to articulate for the kind of display flexibility our customers have come to expect from the line.”

The 3-D exploded sculpt of the Jabba figure.

The figures in the Deluxe line include oversized aliens and figures with vehicles and, Smith says, “Scale is the biggest challenge. We have to generate packaging off of the tallest and deepest characters. Bigger characters also mean heavier plastic weight and require a more defined center of gravity to ensure they will display and articulate properly.”

And then there’s the details; 6-inch figures just have more of them. “At this scale we can really run wild in a way that 3.75-inches doesn’t afford,” Smith says. “Hair especially gets much more attention and detail to ensure we’re getting the right highlights and patterns that normally wouldn’t be included in smaller scales. Surface textures are more intricate because they can really be seen and appreciated. We also try to get more weathering and wear on the figures to get closer to film accuracy.”

There are more deco ops, or paint applications, than on the 3.75-inch figures, and more tampo hits, too. And there’s much more detail on all of the accessories, from buckles to buttons to blasters: “A blaster in 3.75-inch may have been in a single molded color,” Smith says, “but in 6-inch, we add the finer details that really bring it all together.”

The SDCC exclusive throne-room set. A stand-alone Jabba figure will also be available.

In all, making a new figure is a process that involves a number of designers, engineers and product managers, a sculpting team, the model shop, a factory 14 time zones away from the Hasbro crew, and branding and marketing teams. “It takes a village,” Smith says. “ A village of super-obsessed Star Wars fans.”

Not going to Comic Con, but want one of these sets for yourself? You're in luck! A limited number of Hasbro's Comic-Con International 2014 special edition "Jabba" sets will be made available on HasbroToyShop.com following the convention.

nextArticle.image_alt|e
Martin Lewison, Flickr // CC BY-SA 2.0
arrow
fun
20 of the Most Interesting Trees Around the World
Martin Lewison, Flickr // CC BY-SA 2.0
Martin Lewison, Flickr // CC BY-SA 2.0

Whether they bleed crimson sap or uncannily resemble human features, these 20 trees aren't your average oaks and elms.

1. TREE SHAPED LIKE A HAND

The stubby, leafless branches of an olive tree, outstretched and resembling a palm. A man has his palm outstretched next to it.
Ramzi Haidar, Getty

In 2009, a man from the southern Lebanese village of Hasbaya brought his 85-year-old olive tree to Beirut to be displayed. He believed its resemblance to an outstretched palm was miraculous and felt it should be shared with the public.

2. "WORLD FAMOUS TREE HOUSE"

Black and white image of two men standing in front of an enormous tree, with a door with a sign over it that says "See the inside no charge" and a hanging sign that proclaims "Fraternal Monarch."
Getty/Fox Photos

Recognized by Ripley's Believe It or Not! in the 1930s as "the tallest one-room house in the world," this redwood along northern California's Redwood Highway was hollowed out by a fire some 300 years ago. But it's still alive and thriving, and although no one lives there now, the inside is home to some small mechanical toys that you can see for a few coins. Despite the Ripley's recognition, it doesn't appear that anyone actually lived in the house, though a road construction crew stayed there for a week in the 1920s when building the road. If you happen to find that this tree is closed, check out the nearby Living Chimney Tree, which is similar, minus the mechanical diversions.

3. CHAPEL OAK

A towering oak tree with a spiral staircase and two chapels carved into it.
Ji-Elle, Wikimedia Commons // Public Domain

As the oldest known tree in France, Le Chêne Chapelle ("the Chapel Oak") in the village of Allouville-Bellefosse has been around for at least 800 years, and some say it dates all the way back to the reign of Charlemagne. Though lightning struck the tree and rendered its center hollow during the 1600s, the tree managed to survive. A local abbot decided to make use of the hollow by erecting a shrine to the Virgin Mary inside; a second chapel and a staircase were later added. Sadly, the Chapel Oak isn't doing so well these days—the 33-foot trunk has died, and shingles cover the trunk where the bark is missing.

4. DRAGON BLOOD TREE

A large, mushroom-cloud shaped tree with reddish, vein-like branches.
Khaled Fazaa, Getty

The dragon blood tree, native to Yemen, doesn't just look cool from the outside—it also "bleeds" red sap. Because of its crimson color, it's been speculated that the dragon's blood sap was used to give Stradivarius violins their distinct hue.

5. RAINBOW EUCALYPTUS

Skinny tree trunks with brightly colored streaks running down the bark.

It's easy to see why this tree has such a colorful name, but how it gets its bright streaks is not as easy to explain. The ever-changing colors are due to the evolving bark of the eucalyptus. As the bark grows, it exfoliates thin layers of tissue, and as the layers peel off, the fresh, lime green bark underneath is revealed. As the exposed bark ages, it changes to dark green, then blue-purple, then pink-orange. The final stage before exfoliation starts again is a brownish-maroon hue, so the rainbow colors are really just different natural stages of bark development.

6. ANGEL OAK

A huge tree with massive outstretched branches in every direction.
MadeYourReadThis, Wikimedia Commons // CC BY 4.0

At 65 feet tall and 28 feet in circumference, this massive oak tree on Johns Island near Charleston, South Carolina, provides shade to an area of about 17,000 square feet. Oak trees usually grow up instead of out, but since this one is somewhere between 400 and 500 years old, it's had plenty of time to do both. The Angel Oak gets its name from former owners Justus and Martha Waight Tucker Angel, but the tree is now owned by the City of Charleston.

7. BIKE IN A TREE

A tree embedded in the bark of a tree.
Sean O'Neill, Flickr // CC BY-ND-2.0

There's a sad story that goes along with this bike that has been overtaken by a tree with an appetite—it's said that a young boy who lived on Vashon Island, Washington, left his bike leaning against the trunk in 1914, then went off to war, and never came back to retrieve it. Fortunately, it's made up. The real story, according to resident Helen Puz, isn't quite so heartstring-tugging. In 1954, her 8-year-old son, Don, inherited a girl's bike. He wasn't too happy about riding it, so when the bike somehow got "misplaced," Don didn't look too hard for it. Fast-forward 40 years, when Puz read an article in the local paper about a bike that had been lifted five feet off the ground by a tree that grew up around it. She checked it out, and realized that Don's long-lost bike had been found.

8. CROOKED TREES OF POLAND

A series of oddly curved tree trunks that seem to be naturally occurring.

Thought to have been planted in the early 1930s, 400 50-foot pine trees near Gryfino, Poland, bend sharply at the trunk in a manner that has scientists baffled. If the structure was the result of a genetic mutation, the trees would curve in places other than the base. And if the cause was environmental—say, snow weighing down the trunks as they were newly formed—then surrounding trees of the same type and age should have been similarly affected. One hypothesis is that local farmers manipulated the trees to curve for furniture purposes, but were prevented from harvesting them when World War II broke out.

9. THE SUNLAND BAOBAB

A group of people stand in a line in front of a very wide baobab tree
South African Tourism, Flickr // CC BY 2.0

With a circumference of 154 feet, the Sunland Baobab in Modjadjiskloof, South Africa, was once famous for being the widest Baobab in the world. Carbon-dated at around 1700 years old, the tree began to hollow out at around 1000 years old—which made it perfect for a small bar inside. Sadly, a large branch representing about one-third of the tree split off in 2016, causing a lot of damage and permanently closing the bar inside.

10. STRANGLER FIG

A tree trunk with a natural, strange white lattice over it.
Poyt44, Wikimedia Commons // Public Domain

The lattice on the tree above may be beautiful, but it's also deadly—the intricate pattern is actually the strangler fig slowly squeezing the life out of the tree it envelops. The fig tree grows when a bird or other animal drops its sticky seed in the branches of another tree. The seed is able to thrive on the tree's surface, and as it grows, its long roots reach down the host tree and, eventually, into the ground. The strangler fig can be found in tropical and subtropical zones, and is a frequent sight in southern Florida and the Keys.

11. MONKEY PUZZLE TREE

A tall tree with no branches or leaves on most of the trunk, only at the top - it resembles an umbrella. A blue sky with clouds is in the background.

The national tree of Chile is certainly a distinctive one. Though the Araucaria araucana is more pyramid-shaped when it's young, it becomes rather top-heavy as it ages—and it can really age. Monkey puzzles can live to be up to 2000 years old and reach heights of about 164 feet. As a conifer, it produces edible cones called "piñones." Now, about that unusual name: Legend has it that in the 1850s, when the trees were becoming popular as decorative plantings in English gardens, noted lawyer Charles Austin looked at one and remarked, "It would puzzle a monkey to climb that."

12. THE BOAB PRISON TREE

A stout, thick tree with a skinny, vertical knothole in the middle. It's surrounded by a fence.
Martin Kraft, Wikimedia Commons // CC BY 3.0

There's a dark legend surrounding this unique boab tree in Western Australia: It's said that the tree's human-sized knothole made it the perfect prison cell during the 1890s, when Aboriginal prisoners were on their way to Derby for sentencing. Although the tree is on the State Heritage Register as "prison boab tree" and the signage around the tree acknowledges this supposed history, there doesn't appear to be much evidence for the tree being used as a cage.

13. BUDDHA HEAD IN A TREE

A head from a Buddha statue entwined in tree roots.
ironypoisoning, Flickr // CC BY 2.0

No one is quite sure how this Buddha head got so perfectly entwined in the roots of this tree at the Wat Mahathat temple in Ayutthaya, Thailand, but there are plenty of theories. The statue was likely decapitated in 1767, when the Burmese army invaded and destroyed the ancient temple. The temple was abandoned until the 1950s, when restoration work began, and that's when the statue head was discovered. One theory is that the perfect juxtaposition happened to occur naturally when the statue piece fell within the tree roots just right. Another is that a thief placed it there to hide it in the 1900s, which is when part of the temple collapsed due to treasure hunters.

However it happened, the head is there to stay—a guard is now stationed nearby to make sure that souvenir-hunting tourists don't get too grabby.

14. ÁRBOL DE TULE

A wide tree with a circumference of 137.8 feet.

At more than 32 feet in diameter and about 114 in height, the Árbol del Tule in the town of Santa María del Tule, Oaxaca, Mexico, is considered to be the broadest tree in the world. In fact, the Montezuma cypress is so stout that scientists once thought it was actually a few trees that had somehow merged together, but modern testing has revealed that the 1500-year-old tree really is just a single trunk.

15. CYPRESS TREE TUNNEL

A tunnel formed by very tall Cypress trees with a paved road between the two rows.
sodai gomi, Flickr // CC-BY-2.0

Planted sometime around 1930, this Monterey cypress tunnel at Point Reyes National Seashore, a park reserve in Marin County, California, marks a historic wireless transmission site that still stands today.

16. THE CIRCUS TREES

The "legs" of a tree span a sidewalk, creating a tunnel that can easily be walked under.

In 1947, a Swedish American farmer named Axel Erlandson turned his tree-shaping hobby into a tourist attraction. Erlandson, who had a knack for creating living art with trees and plants, was constantly experimenting with grafting trees together and encouraging multiple trunks to grow into one. When he had 60-70 fairly mature examples of artfully twisted trunks and branches, he dug them up and relocated them near Santa Cruz, California. The attraction garnered some attention from Ripley's Believe It or Not! and LIFE magazine, and in 1963, Erlandson sold his grove of "Circus Trees." Sadly, he passed away in 1964 without telling anyone how he shaped the trees. "I talk to them," he was fond of telling anyone who asked.

Though they've passed from owner to owner through the years, these days, the trees are a main attraction at the Gilroy Gardens theme park.

17. DARK HEDGES

Two rows of gnarled trees reaching out over a path.

They're just beech trees, but the gnarled, foreboding tunnel they form has become one of the most popular tourist attractions in Northern Ireland. The trees—about 150 of them—were planted 200 years ago by the Stuart family, who wanted to create an intimidating entrance to their house. Known as "the Dark Hedges," the cluster of trees have made a handful of appearances in TV shows and movies. Hoping to keep the trees healthy for another two centuries, the Department of Infrastructure recently banned vehicles from driving on the road.

18. WINDBLOWN TREES OF NEW ZEALAND

A copse of trees that look as if they are being forcefully blown to the right by wind. Sheep graze in the grass at the bottom of the trees.

These macrocarpa (a type of cypress) trees in New Zealand may look like they're windblown, but they retain their extreme angles even on a calm day. The strange bend is the result of saplings surviving and thriving in the windy environment. The manager of the farm where the trees live says their photogenic branches conceal a secret—the ruins of a house that sheep now use for shelter.

19. THE SCREAMING TREE

A tree trunk with 3 knotholes resembling two eyes and a mouth open in a scream.
Pleuntje, Flickr // CC BY-SA 2.0

This tree in the Bourgoyen-Ossemeersen nature reserve near Ghent in Belgium has knotholes that makes it resemble Edvard Munch's 1893 painting The Scream.

20. THE TREE OF LIFE

A tree perched precariously between two cliffs, with the roots dangling down into the empty space between the two formations.
daveynin, Flickr // CC BY 2.0

Also known as the Tree Root Cave, this tree, located in Olympic National Park near Kalaloch, Washington, has managed to survive even though erosion has removed most of its support system.

nextArticle.image_alt|e
iStock
arrow
Food
Hate Red M&M's? You Need a Candy Color-Sorting Machine
iStock
iStock

You don’t have to be a demanding rock star to live a life without brown M&M's or purple Skittles—all you need is some engineering know-how and a little bit of free time.

Mechanical engineering student Willem Pennings created a machine that can take small pieces of candy—like M&M's, Skittles, Reese’s Pieces, etc.—and sort them by color into individual piles. All Pennings needs to do is pour the candy into the top funnel; from there, the machine separates the candy—around two pieces per second—and dispenses all of it into smaller bowls at the bottom designated for each variety.

The color identification is performed with an RGB sensor that takes “optical measurements” of candy pieces of equal dimensions. There are limitations, though, as Pennings revealed in a Reddit Q&A: “I wouldn't be able to use this machine for peanut M&M's, since the sizes vary so much.”

The entire building process lasted from May through December 2016, and included the actual conceptualization, 3D printing (which was outsourced), and construction. The entire project was detailed on Pennings’s website and Reddit's DIY page.

With all of the motors, circuitry, and hardware that went into it, Pennings’s machine is likely too ambitious of a task for the average candy aficionado. So until a machine like this hits the open market, you're probably stuck buying bags of single-colored M&M’s in bulk online or sorting all of the candy out yourself the old fashioned way.

To see Pennings’s machine in action, check out the video below:

[h/t Refinery 29]

SECTIONS

arrow
LIVE SMARTER
More from mental floss studios