Here is a little description of the process we’re using for designing and building characters for the film.
The characters are designed in the regular fashion, using pencil and paper. Then they’re brought into Flash, where the breakdown positions, segmentation, and turnarounds for the different cut out parts are made up. This allows us to cut at different scales and replace out worn parts that will match up accurately with the originals.
These are then spread out as a layout document in Illustrator and outputted to our die cutter.
And then begins painting and piecing together!