Have you ever wondered where dolls come from? Not geographically — although that can be an interesting story as well — but where a particular doll started and how it came to be?
I’ll be going to Toy Fair in NYC in a few weeks, and for The Pattycake Doll Company this is probably the biggest link in the supply chain for us. I’ll be making a few more posts about Toy Fair, but today’s post is more about ‘where dolls come from’ in general than Toy Fair.
So. Let’s start at the beginning and describe the steps of how those beautiful dolls end up in your children’s loving arms.
- Dolls start as an idea. Whether it’s an entrepreneur who thinks they’ve come up with something new and innovative that the doll market just needs to have, or a long time doll manufacturer like Madame Alexander or Kathe Kruse that wants to freshen up their line or reissue a classic doll for today’s children.
- Next comes the design. A doll artist or doll sculptor or a doll design team starts making sketches and drawings. What could the new doll look like? What will it wear? What features will it have? How detailed shall it be?
- Here is an example of a doll proposal: A 13 inch doll with open and close eyes that has a cloth body and soft vinyl head, arms and legs. We want it to be machine washable. We want one of the hands to have a thumb that will fit in the doll’s mouth so that it ‘sucks it’s thumb.’ We want it to be able to sit by itself, so we want a beanbag insert in the butt. We want it to be for a 12 month old or older. It will need to pass The European, Canadian and US safety regulations so that the one design can be sold in all three markets.
- Once a design is finalized, negotiations begin with the factories. Most dolls are made in China, but quite a few are made in Spain, Eastern Europe, and Pacific Rim countries like Malaysia and Indonesia. Longtime manufacturers will have their regular factories established already, but every year there are new company start-ups who will have to establish their own relationships with the factories. Alibaba is one way for these new doll companies to locate potential manufacturers.
- Costs are agreed upon, samples are made and either returned for correction or approved. There will be a mold made, and then various different colored vinyls will be used, different eye colors will be inserted, the finished features will be decided – like painted cheeks or what color paint for the hair… things like that.
- Clothing will also be decided on at this point. A couple of different outfits will be hand sewn to fit the doll. Safety rules will need to be followed here as well. Using our example of a doll safe for 12 months old, there will probably not be any buttons, bows or ribbons that can be pulled off and swallowed.
- The doll by now will have been named and it’s features settled on, so now the packaging designers will start their part of the process.
- The new doll is manufactured, dressed and packaged.
Next week we’ll pick up from there… the journey from the factory to your child.