The brief
Every autumn a US seasonal-display company sends us a list of the licensed characters it wants for the coming Christmas season. Olaf was on that list — Olaf in a Santa hat holding a candy cane. The client supplies the licence paperwork and the IP holder's style guide, and asks for one thing above all: that the figure looks exactly like the character people know, from across a car park and up close in a photo.
Holiday figures are a different job from a one-off landmark. They go up in October, come down in January, get folded into a bag and go up again the next year — sometimes at a different site. So the brief is as much about durability, packing and repeatable setup as it is about likeness.
Design
We start from the style guide, not from our own drawing. The character's proportions, colour values and permitted poses are the specification; our studio builds the 3D model to those numbers and sends renders for the licence holder's approval before any patterning begins. Stacked snowballs are the hardest shape to keep stable, so the bottom sphere was widened and internally baffled; twig arms and hair are stuffed sewn pieces so they keep their line.
At this stage we also decide what is printed and what is sewn. Large colour fields are printed panels; anything that needs to cast a shadow — hats, ears, hands, props — is made as a separate shaped chamber so the silhouette holds from a distance.
Licensed character · Part of a holiday set
Build
The figure is sewn from printed PVC-coated fabric with double-stitched, folded seams and internal baffles wherever a large volume would otherwise sag. The three spheres are separate chambers joined by sewn collars. Guy-rope loops are sewn at the shoulders and base, and a wide zip near the base lets the client's crew deflate it in minutes.
Because the set will be re-used for years, seams on high-stress areas get reinforced patches and the blower inlet is a fabric sleeve rather than a rigid collar — it survives being folded into a bag every January.
Test inflation
Every figure in the set is inflated on our factory floor before it ships. The candy cane and arms were checked for droop after ten minutes of inflation. We photograph it from four sides with a worker beside it for scale, check seam tension, lean and colour against the render, and send the photos to the client for sign-off.
Only after approval is the figure deflated, folded on a clean mat and packed with its blower, ropes, repair kit and storage bag.
Result
The figure shipped to the USA with the rest of the holiday set in one consignment and has gone back up every season since. For us the real result is the repeat order: the same client comes back each year with a new list.
