⚔️ 4-Knight Action Figure Series

Project Overview

Premium 4-knight action figure series featuring intricate armor details, multiple articulation points, and collector-grade paint applications. Each knight includes interchangeable accessories and display base.

Technical Highlights

• 9-set mold system: Optimized for cost efficiency while maintaining quality
• 500-cycle joint test: Ensures consistent articulation tension
• Complex paint masks: 15+ separate paint operations per figure
• Interchangeable parts: Magnetic weapon attachments, swappable heads
• Custom packaging: Window box with foam insert for retail display

Manufacturing Process

1. 3D modeling and DFM optimization
2. Rapid prototyping (SLA 3D printing)
3. Hand-sculpted master approval
4. Steel mold fabrication (hardened steel, 500K+ cycles)
5. T1 samples (raw plastic) for fit check
6. Painted samples for color approval
7. Mass production (injection molding, paint, assembly)
8. QC inspection (AQL 2.5 standard)
9. Packaging and shipment

🦸 8-Inch Articulated Character Figure

Project Overview

Flagship character figure for North American client’s Kickstarter campaign. Features highly detailed sculpting, complex paint applications (skin shading, costume details, weathering), and robust articulation for dynamic posing.

Technical Highlights

• Spectrophotometer color matching: Consistent skin tone across all 3,000 pieces
• Multi-material assembly: PVC body + ABS joints + TPE soft parts
• Complex paint: 20+ separate operations including airbrush shading
• Quality control: 98.5% pass rate on first inspection
• Direct-to-backer shipping: Custom blister packaging for individual fulfillment

Client Feedback

“Zhenghui treated our 3,000-piece order like it was 30,000. Quality exceeded our backers’ expectations — we’re already planning Wave 2!”

🗿 1/4 Scale Resin Statue with LED Base

Project Overview

Premium resin statue for European museum’s exhibition gift shop. Museum-grade quality with hand-painted finish, LED-illuminated stainless steel base, and custom foam packaging for retail display.

Technical Highlights

• Hand-sculpted master: Started with traditional sculpture (not 3D printed) for finest surface detail
• Vacuum casting: High-grade polyurethane resin for consistent quality
• Senior painters: 10+ years experience painters handled all 200 pieces
• LED integration: CE-certified LED modules, ESD-safe assembly, 100% function testing
• Zero defects: 200/200 passed final inspection

Result

Sold out in 3 weeks at museum shop (€299 retail). Museum commissioned 2 additional statues for next exhibition.

🎁 8-Design Blind Box Series (Vinyl Figures)

Project Overview

Complete blind box series for UK lifestyle brand’s entry into collectibles market. Includes 8 unique designs, custom blind box packaging, and epoxy display cases. Launched in 50+ UK retail locations.

Technical Highlights

• Design for manufacturing: Reviewed 2D designs and optimized for vinyl casting
• 8 separate molds: One per design for flexible production scheduling
• Randomization system: Secure process preventing “box weighing” by retailers
• Packaging design: Structural design + drop testing for retail shipping
• 85% sell-through: In first 3 months at retail

Result

Successful retail launch led to EU and US market expansion. Second series commissioned (12 new designs).

💡 Complex LED Assembly — Display Piece

Project Overview

Complex assembly project integrating LED lighting effects into resin display piece. Features multi-color LEDs, battery-powered switch control, and transparent resin light guides for dramatic illumination effects.

Technical Highlights

• LED module sourcing: CE-certified modules from trusted suppliers
• ESD-safe workstation: Prevents static damage to electronic components
• Function testing: 100% of units tested before packaging
• Battery compartment: Secure design with easy access for replacement
• Light diffusion: Custom resin light guides for even illumination

Capabilities Demonstrated

This project showcases our ability to handle complex assemblies beyond simple injection molding — integrating electronics, managing multiple supply chains, and ensuring reliable function across production runs.