Hey guys. Thanks.
The sculpting of these dinos were started and completed in Zbrush. Hasbro has many internal Zbrush users as well as a host of mechanical experts that work out the function and articulations of the toys. The larger Green dino had the most mechanical components of all of the sculpts that I worked on. The art director and I discussed the price points of the toys, how much articulation and mechanical components we could have in the toys. The Green one has lights, sound and 5 points of articulation while some of the simpler ones have only 2 points of articulation with no sound or lights. More bells and whistles = more cost.
There were several advantages of working in Zbrush for the project verse traditionally or with other sculpting packages some of which were that we could do many different variations of articulation adjusting for cost or exploring different ideas for movement, change sizes quickly and make edits in minutes. Saving time...saving money.
In the end some sculpts were used with a lot of articulation at medium to larger sizes but also the same sculpt minus the articulation points were used at smaller sizes. Same sculpts but just without all of the different components thereby offering another product to put in the cart. Zbrush was a champ through the entire project! There's simply no way that I could have done this project with it.
The general process went like this:
The art director approached me with the project to do some initial character sketches of the dinosaurs that he had in mind. This is for Playskool so they had to be cute and fun. As posted above I generated some 2D sketches of the dinos and made some general color suggestions. The art director gave some notes about the line up of characters and we presented the results (sketches) to the team. They love the sketches and gave me the green light to do the sculpting. Before starting the sculpting my AD and I discussed price points, articulation, deco and colors. Then the sculpting began. For the larger dino (Green one) a foam model was built internally so that the mechanisms could be established. That was handed off to me then (photos only) to do the digital sculpt. I did not do any of the internal structures for the mechanical components. That's the job for the engineers. My job was mostly aesthetic. Make them mean but in a 'cute' sort of way I think is how it went.
Anyway, here are a few breakdown images of how the project came together in Zbrush.
Some really neat videos of the internal mechanisms for the dino.