The 3D scans are then run through a stereo lithography machine. A stereo what-now? Well, just think of it as a 3D printer that layers and shapes resin into an exact real-world model of the star's head.
Those model heads still go back to the stars for approval, but they're so accurate they can't really complain too much. “Dennis Quaid can't say to me, 'Well, my ears look all floppy!'” says model shop boss Marc Millspaugh. "Because I can say to him, 'Well, dude, that's because your ears
There were virtually no problems on GI Joe though – the stars, especially the boys, loved the idea of being turned into toys. “Channing Tatum was, like, 'I'm an action figure! Kids are going to be playing with me!'” says Michelino Paolino. “Marlon Wayans who plays Rip Cord was the most excited, though. I don't think any of his brothers have got action figures yet.”