Case Study: Gentle Giant achieves 6–8 week cycle-time reduction and faster time-to-market for lifelike WWF figures with 3D Systems' Geomagic FreeForm

Gentle Giant Uses Geomagic Freeform To Deliver Lifelike Wrestling Figures

Gentle Giant, the entertainment division of 3D Systems, was contracted by Jakks Pacific to produce a line of WWF action figures and needed to deliver lifelike, licensor-approved characters quickly. Their workflow relied on laser scans of existing models or live subjects, but scans introduced artifacts and lost fine details in occluded areas, and traditional polygon-by-polygon cleanup was slow, tedious, and often impractical.

Gentle Giant implemented Geomagic FreeForm to “digitally retouch” STL scans using touch-enabled, sculpting-style tools that let artists carve away artifacts, recreate fine features, and modify poses intuitively. The team refined over 50 head scans in days, exported finished STL patterns for production, and achieved a 6–8 week cycle time reduction — cutting costs, accelerating time-to-market, and delivering high-fidelity figures that satisfied the client.

Gentle Giant

Karl Meyer

President