The desired mould is mounted into an injection moulding machine. Then polymers or plastic pellets are introduced in the machine for melting. This process results in the pellets blending with the dye at high temperatures and forming a thick paste. This paste or hot molten plastic is then shot by the machine into the desired moulds. This is the process followed by the toy manufacturer.
The steps involved in toy manufacturing are given below.
The concept plays an important part in the design and manufacture of toys. The factors determining the concept are the demand and popularity of different toys and current market trends.
Once the concept is approved the next step is the design process. The prototyping process uses a mix of 3D modelling, rapid prototyping, hand sculpting, moulding, and casting. Once the prototype is approved the color and size of the toy is decided followed by the packaging design.
The people involved in the design and prototyping process include artists, sculptors, engineers, and craftsmen, with a background in the toy manufacturing process.
The following approaches are used in the process of prototyping.
a) Hand sketches and illustration.
b) Digital sculpting or 3D modelling.
c) Rapid prototyping or 3D printing or Stereolithography (SLA).
d) Hand sculpting.
e) Moulding and casting.
f) Air-brushing and hand brushing.
g) Hand patterning and sewing. This is used for plush toys.
h) Graphic design, package-mockups, and proofs.
Initially, the individual components of the toy are fabricated which is followed by assembly. The finished product is then checked for quality and safety norms prescribed. On passing the required safety and quality norms the product is then packed.
The toy manufacturer then starts shipping the finished product.