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Alex Riley witnesses the toymaking process at Mattel Headquarters

The WWE action figure process begins with Gentle Giant Studios technicians, who scan the subject - in this case, WWE Superstar Alex Riley.

Cameras affixed to each lever capture the distance between the beams and Riley, thus rendering his digital likeness.

Separately, a head-only scan exacts physical details of the face, hair and complete head.


Digital sculptors take the raw visual captured by the scan and refine the rendering.

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After computer editing, sculptors hit "Print" and a three-dimensional output of the molding starts to cook in an oversized printer.


In the 3-D printing room, A-Ry gestures toward other celebrities who've been immortalized in action figure form by Gentle Giant such as Samuel L. Jackson and Jessica Alba.

The 3-D printed material is passed off to casters, who carve off excess resin and shape the figure molding.



Miles away from Gentle Giant, A-Ry touches down at Mattel's world headquarters in El Segundo, Calif.

Inside the toymaking halls of Mattel, Alex Riley encounters every Basic Series WWE action figure made in 2010.

By the day's end, Riley's own likeness will appear beside these plastic powerhouses.

Next up in the process is the skilled paint application, which Mattel lead designer Bill Miekina demonstrates.


Designers use reference material - tons of photos - supplied by WWE to determine the look of a figure.


Much design work is handled digitally for easy alteration and file transfer to Mattel's global manufacturers.

Some serious assembly is required and handled by Mattel's partners, yielding ...

... the finished product.

The detail of Riley's attire and tattoos astound the young Superstar.

As they position the figures using an adhesive substance, packaging engineers break the news to Riley that he'll come in a Battle Pack with his ex-boss, The Miz.

Elsewhere, a creative team meticulously designs the box art, including dramatic Superstar photos shot by Mattel specifically for their 2012 product lines.



Alex Riley officially joins the likes of Randy Orton, Shawn Michaels, John Cena and Rey Mysterio with his very first WWE action figure.


A-Ry discovers his two-piece Battle Pack on store shelves, just like members of the WWE Universe will soon enough.
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