Patent Publication Number: US-2018036645-A1

Title: Method for making a custom poseable, full body action figure with customized recloseable packaging

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This is a perfection of U.S. Provisional Application Ser. No. 62/370,312, filed on Aug. 3, 2016, the disclosure of which is fully incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to customized figures or bendable/contortable dolls. More particularly, it relates to such figures that have been made to resemble a particular person whose likeness has been supplied by a customer. The likeness can be made, via 3D printing, to fit on a body build similar to that requested by the customer. This custom figure is meant for both Display AND Play purposes. 
     This invention further relates to a method of customizing packaging for that figure or doll so that: it contains statistics, stories and/or other particulars specific to the particular person; and it can be stored in a resealable/reclosable packaging. This custom packaging is meant for both Display AND Play purposes. In fact, in one preferred embodiment, the individuals depicted on the rear of the package, playing with the doll, can be computer modified (i.e., “Photoshop-ed”) to be actual friends or relatives of the customer. It may also be possible to order just a GoFigure!® toy/doll without the aforementioned custom packaging. 
     Relevant Art 
     Numerous references pertain to doll making and/or bobblehead manufacturing. These include, in chronological order: Penberthy et al. U.S. Pat. No. 5,803,788, Kimbrough et al. U.S. Pat. No. 5,926,388, George et al. U.S. Pat. Nos. 6,071,171 and 6,099,378, Bailey et al. U.S. Published Application No. 2008/0214168, Sullivan et al. U.S. Pat. No. 7,722,431, Silva et al. U.S. Pat. No. 8,172,638, Sandholt U.S. Published Application No. 2012/0252305, Tobias U.S. Published Application No. 2013/0045659, Currie et al. U.S. Published Application No. 2013/0080287, Hodgins et al. U.S. Published Application No. 2013/0226528 and Lauer U.S. Published Application No. 2015/0231516. While the latter reference takes a customized head and sticks it onto a pre-fabricated, action figure body, it does NOT include the customization of the body to which the customer&#39;s head is mounted in a swiveling/rotating manner. Nor does it address the customization of action figure accessorizing and the custom resealable (optional) packaging for the same like that of the present invention. 
     BRIEF SUMMARY OF THE INVENTION 
     This invention relates to a method for making customized action figures, with pose-able bodies AND heads, for placement in customized packaging that can be repeatedly closed and opened for doll removal and play. The method includes: sculpting a preferred body shape from a variety of doll parts; painting the sculpted body for customized apparel; making a realistic doll head from one or more customer-supplied photographs; and attaching the doll head to the sculpted body so that it may swivel about. That fully assembled head and body are then placed in a custom printed, reclose-able package. Optional additions include: making custom accessories for the action figure based on customer-supplied requests; including custom sewn or sculpted clothing and/or accessories, and using custom graphics and layout designs in the packaging. 
     The body-sculpting step currently entails “cannibalizing” existing doll parts via a process called kit bashing that includes shaving unnecessary details therefrom and/or adding epoxy-made alterations though not necessarily in that order. Eventually, specially made sculpts of a pre-set collection of body components will simplify the body assembling sub-step further. 
    
    
     
       BRIEF SUMMARY OF THE FIGURES 
       Further features, objectives and advantages of this invention over the art will be made clearer with the following Detailed Description made with reference to the accompanying drawings. Common components between embodiments are commonly numbered though in the next hundred series. In these drawings: 
         FIG. 1.1  is a side-by-side photograph of a representative full body action figure, item  10  therein, one actually made for an Indiana Jones series of figures, before it has been Boiled &amp; Popped; with that same action  FIG. 10  separated into respective component body parts, namely a main trunk  12 , waist  14 , left and right upper arms ( 16 L and R, respectively), left and right forearms ( 18 L and R), left and right hands ( 20 L and R), left and right calves ( 22 L and R) and left and right feet ( 24 L and R), after Boiling &amp; Popping, to the immediate right of the main body (with its original head H) in this side-by-side view; 
         FIG. 1.2  shows a representative Iron Man action figure body  110  for custom tapering of that doll&#39;s waist W and the purposeful addition of a bust line B with hobby epoxy for making it into more of a woman&#39;s body shape (including her customized head H) before custom painting; 
         FIG. 1.3  shows a first representative front  50 F and rear  50 R (retail style) custom packaging for inclusion with a customized action  FIG. 210  per the present invention, the front  50 F of said packaging including: the individual&#39;s name N, a recloseable case  52  into which action  FIG. 210  is secured, a card front having a cartoon-like version  54  of the same individual, the inventors&#39; GoFigure! logo L, and a retail-style display hanging hook  56 , the rear  50 R of that same packaging including some representative particulars for the individual such as his date of birth  60 , hometown  62 , height  64 , “super powers”  66 , arch nemesis  68  and a space  70  for a short Narrative on the individual, said rear  50 R further including a customized photograph  80  showing two individuals  82 ,  84  playing with the action  FIG. 210  along with a representative QR reader packaging code  90 ; 
         FIG. 1.4  is a side view showing one representative clear plastic clamshell  330  for resealable packaging that action  FIG. 310  (actually one of the co-inventors), wearing a custom made hat  340 , cloth coat  342  and cloth pants  344 , along with a rifle accessory  346  per another embodiment of this invention; note the use of a bottom hinge  332  and optional peg hook display hole  334  at the top of plastic clamshell  330  (alternately, a bubble box may be substituted for clamshell  330 ); 
         FIG. 1.5  is a representative larger scale action  FIG. 410  made according to this invention, said 12″ doll being packaged in either a retail style, recloseable box  430  or clear plastic tube  436 ; 
         FIG. 1.6  is a second representative front  550 F and rear  550 R (retail style) packaging card according to this invention depicting the individual&#39;s nickname NN, a cartoon drawing  554  of the party for whom action  FIG. 510  was requested, that action figure further including a rifle  546 R and ketchup bottle  546 K accessory, the rear  550 R of said packaging showing the same two individuals  82 ,  84  playing with action  FIG. 510 ; and 
         FIG. 1.7  is a third representative front  650 F and rear  650 R (retail style) packaging for a customer that included a computer generated (i.e., Photoshop-ed) picture of actual relatives  682 ,  684  playing with his own customized action figure doll  610 .  FIG. 1.7  also replaced our standard background with a rendering of where the individual, a doctor, worked, i.e., his job site JS (or hospital) and included a logo BB for a particular “Boot the Bug” campaign at that hospital that the customer had worked on. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     GoFigure! offers two different sizes of custom action figures: 3.75″ (1:18 scale) (commonly rounded up to 4″ for simplicity) and 12″ (1:6 scale). Unless otherwise stated, all process explanations are the same for both sizes. With rare exception, each GoFigure! product is a one-of-a-kind unique piece of hand crafted, functional art. While some components may have been mass-produced, the customized elements are done by hand on a small scale. 
     1. Figure Body Sculpting 
     We modify a process called “kit bashing.” Traditionally, kit bashing is mixing and matching various parts from different action figures. We add to this process by sculpting the various figure parts to better match our clients&#39; body type using both reductive and additive processes detailed below: 
     1-A. Boil &amp; Pop 
     First, we separate the existing toy through a process called “boil and pop”, which is where we place a figure in stove-heated (but not quite boiling) water with some dish soap, softening the joints and allowing us to separate them into individual pieces (arms, biceps, torso, thigh, calf, foot, etc.). 
     1-B. Sculpting 
     Once the figure is broken down to its smallest components, we sculpt or shave/shear whatever additional components are necessary (such as but not limited to sculpting breasts or a larger stomach on a male chest, sealing gaps in the original figure&#39;s sculpt to change its shape, etc.). We do this sculpting with a special hobbyist epoxy called Kneadatite® (“green stuff”) and/or plumbers epoxy or modeling/sculpting epoxy. Once the additive sculpt is dry, we pop it off and reapply it using adhesive to create a permanent bond to the figure. Many times, reductive sculpting work is also required to custom shape a figure using a rotary tool such as a Dremel® and/or an X-Acto® hobby knife (or their equivalent) to shave the pieces into their desired shape. That includes creating curves on a male figure, removing shirt pockets or collars, etc. We then smooth out all remaining pieces using the rotary tool and successive ultra fine grit sand paper and sand the figure smooth. If there are any permanent joints that could not be separated during the boil and pop phase, we sand those down by 1-3 mm so the figure&#39;s joints can move about freely after they have been painted. There is no precise order to additive vs. reductive sculpting; each varies based on the needs of a particular order. 
     1-C. Painting 
     After each individual piece is shaped and smoothed, we apply 1-3 coats of an acrylic model primer. Once those layers of primer dry, we then paint each individual piece with 1-3 layers of acrylic model paint. When the model paint is dry, a final 1-2 layers of clear model paint sealant is applied. Depending on the needs of the client, the sealer can be full gloss, semi-gloss, or flat. 
     1-D. Reassembly 
     Once all pieces are fully dry and the joints have been tested to ensure full range of motion without paint chipping, we reassemble the figure using the boil and pop method and/or a heat gun (to make the plastic supple and reduce the risk of breaking or damaging the joints). 
     1-E. 12″ Figure Differences 
     Most 12″ GoFigure! Products do not require the boil &amp; pop method. For these figures, we purchase a high quality 12″ doll body such as a “True Type” doll body. We affix the head in a similar manner as described below in section 2.2, and we clothe it with custom clothing as described below in section 3.3. Additive and/or reductive sculpting (and thus smoothing and painting) are sometimes required. These are done as described above in sections 1-C &amp; 1-D. 
     2. 3D Printed Head 
     GoFigure! Custom Action Figures are a blended technology of real action figure plastic from the neck down, and a photorealistic 3D-printed head. Due to the current limitations of conventional 3D printing (visible striation lines, monochromatic printing), we employ a Gypsum Powder 3D Printing process to print appropriately sized photorealistic action figure heads that closely resemble our clients. Gypsum Powder 3D printing has many advantages including full color and minimal resolution lines, but its primary drawbacks are cost and size. Since owning a gypsum powder 3D printer is not currently feasible, we presently order our heads through a third party vendor; ThatsMyFace.com but anticipate making these critical components directly in the near future. This process is the same for 1:18 scale figures and 1:6 scale figures. 
     2-1. Head Production 
     Our client submits 1 or more photos of their face based on guides that the vendor has prepared and allowed us to use on our website. Once we have a suitable front-facing photo and profile (side) photo, we upload them to ThatsMyFace&#39;s website and select: (a) the hairstyle that most resembles our client&#39;s desires and; (b) the neck style compatible with our action figure bodies. Once this is all selected, we place our order with ThatsMyFace. 
     2-2. Head Connection 
     The neck cavity of the ThatsMyFace comes empty, so we need to create a joint that allows it to fit snugly on the action figure body while still retaining range of motion. ThatsMyFace recommends to its clients to simply super glue the head in place, which does not allow for an articulated head motion. Instead we fill the head cavity with hot glue, wait for it to congeal slightly while still being malleable, then place it on a neck joint compatible with the action figure our client will be receiving. The doll proper will have been previously coated in petroleum jelly to protect it during this processing step. Then, we spin the head around the neck until the hot glue cools, creating a perfect-fitting ball joint cavity. That may result in some hot glue overflow around the base of the head which we trim off with a hobby blade. 
     2-3. 12″ Head Connection Differences: 
     The neck joint varies for many 12″ doll bodies depending on that particular vendor, so the process may differ slightly for each manufacturer&#39;s 12″ doll body. But the process is essentially the same: “supergluing” or otherwise permanently affixing a neck joint inside the neck cavity of the 12″ doll head with a little protrusion or recess (as required by the 12″ doll body neck joint) so that the neck joint can connect to the corresponding ball joint or swivel joint on the 12″ doll body. On occasion, this may require re-shaping the neck with a rotary tool, blade tool, and/or sand paper. 
     3. Accessories 
     Our figures can come with accessories chosen by the client. If the accessory they desire is not available in our lot of pre-manufactured accessories (such as guns and light sabers collected from other action figures), we will custom sculpt &amp; paint the accessory ourselves using a similar process as detailed in sections 1-B and 1-C above. Other representative accessories include: cell phones, swords and laptops. 
     3.1 Sculpting &amp; Painting 
     When appropriate, we will sculpt a custom accessory out of Kneadatite® and/or sculpting epoxy. It is entirely possible to incorporate mixed mediums such as hot glue, fabric, thread, and decals. Once the accessory is sculpted, it is smoothed with sand paper and a rotary tool, then primed, painted and sealed. Occasionally, we may re-paint an existing accessory without any custom sculpting such as when replicating a pet. 
     3.2 Decals 
     Often times our clients request that their figure wear a shirt with a certain image on it, or that their accessory match the details of its real life counterpart. When appropriate, we design and print out a vinyl decal in the appropriate size and adhere it to the figure or accessory. 
     3.3 Cloth Clothing 
     An optional accessory for 4″ figures and a required accessory for 12″ figures is cloth clothing. When not readily available or cost effective, we will custom sew (or commission to be custom sewn from a GoFigure! vendor) actual material clothing that, to the best of its ability in regard to scale and skill, replicates the client&#39;s actual or desired item of clothing. Occasionally, a decal is required on such clothing. When it is not feasible to use the vinyl decal meant to adhere to rigid plastic, we will use an “iron-on” graphic. We may also offer embroidery and/or silk-screened graphics in a small scale or small production run. 
     4. Retail-Style Packaging 
     Depending on the product “level” ordered by the client, special packaging is required that mimics retail packaging but has the built in feature of being resealable without causing damage to the packaging. 
     4.1 Graphic Design &amp; packaging shape 
     GoFigure! has designed its own action figure pad packaging partially inspired by super hero action figure packaging like the 1990s “Power of the Force” line of Star Wars® action figures. Despite this apparent homage, the standard GoFigure! action figure packaging has its own unique dimensions and attributes. GoFigure! also offers a product level where clients can reject our standard packaging in favor of a new shape. Sometimes clients provide precise dimensions, other times only a vague idea or other products of inspiration. GoFigure! will then be responsible for engineering a successful original package design for that client&#39;s order. 
     For product level 4, clients can keep the standard GoFigure! package shape (for both 12″ and 4″) but replace our graphics and layout with anything they want. One example replaced the two tone blue GoFigure! “starburst” with flame licks FL, and the GoFigure! logo with a BMW symbol that incorporates the individual&#39;s nickname NN (see example,  FIG. 1.6 ). In another instance, a doctor&#39;s wife ordered the customized product for him in which we replaced: our typical two-tone blue starburst with a picture of his hospital or job site JS, and our GoFigure! logo with a “boot the bug” logo BB for the campaign that her husband&#39;s hospital was then running (see  FIG. 1.7 ). For further package customization, the image of the two children on the rear of the blister pack was replaced with pictures of the doctor&#39;s own kids holding their dad&#39;s doll/action figure. 
     4.2 Artwork &amp; Creative Writing 
     Depending on the product “level” ordered by the client, we commission an artist to create: (a) a caricature of our client in a “comic book” style drawing  54 ; and (b) a professionally written, action-packed narrative  70  based on questions the client filled out during the order process. Using the pieces provided by our writer and artist, we then mockup a package that includes the caricature on the front &amp; back, personal statistics for our client on the back (such as hometown, date of birth, height, superpowers, arch nemesis, weaknesses (or Kryptonite), favorite colors/foods, etc.), the creative writing bio, and an original image of two children (actually nephews of one co-inventor) playing with the client&#39;s figure achieved by Photoshop-ing a completed figure into the hands of the children. Once the mockup is complete, we bring the file to our professional printers who print the packaging on bonded 18 point stock on an Indigo press similar to the process major corporations like Hasbro and Mattel use, emulating the same quality as a store-bought figure. 
     4.3 Blister Bubble 
     Once we retrieve the completed action figure pad from the printer, we affix a plastic clamshell-style blister bubble to the designated figure area with glue, after puncturing 2 holes in the back of the blister bubble and stringing a clear tie with a metal core (“twist tie”) there through. In that manner, the figure can be tied into the package but also removed for play and reinserted non-destructively. The blister bubble may have a pull-tab in the upper corner and a perforated, rounded, or folded edge on the bottom to allow for repeated opening and re-closing without causing damage to the action figure pad (as otherwise happens on a traditional retail action figure package where the blister bubble is glued directly to the pad). 
     The blister bubble we use comes from a vendor whose intended purpose is to display unpackaged (“loose”) action figures. It was our idea to combine this technology with an action figure pad to mimic “retail-style” packaging. Depending on the product “level” ordered by the client, we may not affix the blister bubble to an action figure pad. In cases when the blister bubble is the complete packaging, we will affix a sticker on the back of the clamshell with our website, logo, and social media names. 
     We will also use a blister bubble that has a peg hook display hole punched at the top. Depending on the needs of the client, a wider, taller and/or deeper blister bubble than the one submitted in the glossary of images may be used to accommodate larger figures, accessories and/or instances where multiple figures must be packed together (e.g., for wedding cake toppers). 
     4.4 Complete Packaging 
     Once the blister bubble is affixed, we use fugitive glue (more commonly known as credit card “booger glue”) to affix the display stand and accessories to the inside of the clamshell blister. We then tie in the action figure and close the re-sealable blister bubble. The action figure is now complete. The method of using a generic plastic tray insert with a cavity for the action figure and accessory or accessories (as is done with retail action figures) may also be employed. 
     4.5 12″ Figure Packaging 
     All the elements described above in sections 4.1 &amp; 4.2 are still done for the 12″ figure box, however instead of a re-sealable blister bubble on a flat action figure pad, GoFigure! 12″ dolls are packaged in retail-style doll boxes. As stated above in section 4.1, “GoFigure! also offers a product level where clients can reject the standard GoFigure! packaging in favor of a new shape. Sometimes clients will provide precise dimensions, other times only a vague idea or other products of inspiration and GoFigure! will be responsible for engineering a successful original package design for that client&#39;s order. This product level is also available for the 12″ doll product. When retail style packaging is not ordered for 12″ figures, they are packaged in clear tubes with removable caps on either end. 
     5. Future Developments 
     GoFigure! has active plans for growth and changes to its product lines and features. 
     5.1 Figure Construction 
     GoFigure! intends to commission original sculpts of “universally compatible” and compatible 1:18 scale action figure parts that can be mass produced to streamline the labor involved in the customization process detailed above in sections 1-A, 1-B, 1-C, &amp; 1-D. We hope to address the absence of diversity of body types in male and female figures and the absence of gender diversity vis a vis a lack of fully articulated female action figures on the market. At this time, we intend to have the following torso styles and accompanying universally compatible limbs:
         Skinny Male, nude   Skinny Male, T-shirt   Skinny Male, suit   Skinny Male, polo   Large Male, nude   Large Male, T-shirt   Large Male, suit   Large Male, polo   Skinny Female, small chest, nude   Skinny Female, small chest, T-Shirt   Skinny Female, small chest, suit   Skinny Female, small chest, polo   Skinny Female, large chest, nude   Skinny Female, large chest, polo   Skinny Female, large chest, T-Shirt   Skinny Female, large chest, suit   Large Female, small chest, nude   Large Female, small chest, T-Shirt   Large Female, small chest, suit   Large Female, small chest, polo   Large Female, large chest, nude   Large Female, large chest, T-Shirt   Large Female, large chest, suit   Large Female, large chest, polo       

     5.2 Sizes Offered 
     GoFigure! also intends to offer a 6″ (1:12 scale) product line, including the original GoFigure! universally-compatible body and limb styles detailed in section 5.1, as well as kit-bashed components. 
     5.3 Packaging Security Features 
     In an effort to make the unique GoFigure! resealable packaging commercially viable, GoFigure! intends to develop  2  security features meant to be used in tandem or alone: 
     5.3.1 Glue Dot Security 
     In the corner of the pulltab of the clamshell blister bubble as detailed in section 4.3, GoFigure! would implement a dab of hot glue or other strong adhesive that would require conspicuous strength and energy to open without destroying the packaging. This would deter those who intend to open packages in retail stores. Alternative to a dot of glue in the corner by the pull tab, it could be a bead of glue running down the side of the clamshell. To avoid package destruction, a lower tack glue (such as fugitive glue) would be recommended for the bead. 
     5.3.2 Adhesive Sheet Security 
     This security model involves a low-tack no-residue clear adhesive sheet to be applied over top of the figure, such that it could be peeled back without damaging the packaging. Such wrapping would require conspicuous strength and energy if someone tried opening the package in the middle of a retail store aisle. Alternatively, the wrap can be a fully-encapsulating, non-adhesive plastic sheet, vacuum sealed or heat sealed around the recloseable blister bubble. 
     5.4 Embroidery and Silk Screening 
     Should it become economically sensible, GoFigure! plans to add embroidery and silk screening features to its cloth accessories. 
     5.5. Plastic Heads 
     As 3D printing technology steadily improves and innovates, it is impossible to predict what type of materials will be able to be 3D printed in full color and with minimal resolution lines. Ultimately, it is GoFigure&#39;s goal to print its 3D heads that resemble our clients in full color in a plastic material that looks much more congruous with the rest of the figure as well as comparable to retail action figures, while still maintaining the level of detail such that the figure is undeniably that of our client. The same can be said for making customized 3D-printed “accessories”. 
     Having described the presently preferred embodiments, it is understood that the method steps making up this invention may be otherwise addressed per the attached claims.