Thank you for all the comments - had taken notes and some being followed up by our studio team.
Being a design studio, it is difficult to please everyone, including the bossman! While we have the freedom to create what we wanted to a certain degree, we do have a lot of constraints throughout the whole process.
Design Phase - With the available references and data, trying to consolidate components from several variants into a single "vehicle". Also need to check historical photo with museum/collector vehicles. Sometimes (which is rare) we have to omit features or try to fake it to make the kit multi-variant.
Prototype Phase - Depending on the number of sprues per kit, we have to make good use of limited space to fit everything onto these sprues. Some parts needed to be combined or simplified for mould making.
Mould Making Phase - Mould release angle is our biggest enemy. All parts are designed with mould release angle in mind. Facing of parts played an important role on how fine details each part can be. Making figures require a totally different approach and mould making process.
Other factors affecting production or alterations include:
- overall production cost per project
- extra cost to amend design
- extra cost to change/modify mould
- importance of making amendments
- time to market
For example, a multi-slide mould is an excellent solution to create very nice one-piece track; but that will increase our total production cost by over 30%... just for that two particular parts! Then come the critical decision - should I have better tracks or an extra sprue for all the other variants? Truck cabin is a totally different story, a multi-slide mould improve assembly experience and model integrity; but to keep cost down, accompanying sprues had to be limited to one or two at max.
This is the type of design & production considerations we faced everyday.