Logan Paul's entry into WWE's army of action figures has been long-awaited, and the process to bring it to life is far more complex than most people think. When Logan Paul made his WWE debut in 2021, it was only a matter of time before he was immortalized the same way most WWE superstars are: with his own Mattel action figure.

But Paul is not getting a simple figure from the company's line of Basic or Elite toys. Instead, he's starting at the top, with WWE and Mattel creating an Ultimate collection figure that is the most-detailed and articulated line of toys that WWE has.

Mattel's creation of Logan Paul's WWE Ultimate collection action figure

The process to create the Ultimate collection figure is a complex one that begins with taking many pictures of Paul.

The design team uses what they call a 3D virtual studio, a portable scanning rig capable of taking 64 photos simultaneously. This studio gives them the ability to capture every single angle of a facial expression, and the team first brought Paul into their headquarters to be scanned.

A scanning session could take up to a few hours, as superstars are asked for a number of facial reactions. Some of them are not used, while others wind up on the toy heads included with the figures. 

Once the photos are taken, the Mattel designers have to render the photos as a singular 3D image, which takes a lot of computing power. The end results leave the company with a full rendering of the talent's head in 3D, viewable from any angle.

After that, the body and clothing design process begins, and then it's off to the 3D printer. Mattel has an impressive collection of 3D printers in its Southern California workshop, all of which are used to print different things.

The earliest prototypes are created in a PolyJet 3D printer. Printing a single figure in the machine could take over 10 hours, as what's being printed is actually incredibly thin layers of plastic.

There are other printers for rubber elements, as well as a much larger machine used to print out prototypes for things like stage and ring pieces.

Throughout the process, designers check on the prototypes, making tweaks to the design based on how it looks and feels. They can even test different types of rubbers and plastics for the prototypes until they find what works just right.

Logan Paul WWE Action Figure

The 3D printing process has revolutionized the toy industry, making it much easier and quicker to make changes to designs.

Prior to 3D printing, when prototypes were all hand-sculpted, even a tiny change could result in the designer having to start their sculpture from scratch, resulting in plenty of lost time.

Now, making a change to a design could take as little as 10 minutes.

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Mattel's Logan Paul Ultimate collection figure is expected to arrive in the third quarter of this year.

Without the scanning and 3D printing technology that is powering these action figure lines now, there's no telling how long such a detailed toy would have taken otherwise--or what kind of impact they would have on all of the other Ultimates, Basics, and Elites WWE and Mattel are planning to release this year.

Overall, the process to create action figures may be a far more involved process, but the results speak for themselves.

Mattel is creating the most detailed and lifelike WWE figures of all time at this point, and the technology is only going to get better in the years to come.

The Logan Paul Ultimate collection figure is just the latest in a long line of WWE action figures that showcases the power of 3D printing and scanning technology to bring the most-detailed and articulated toys to life.