We present a semi-automated system for fabricating figurines with faces that are personalized to the individual likeness of the customer. The efficacy of the system has been demonstrated by commercial deployments at Walt Disney World Resort and Star Wars Celebration VI in Orlando Florida. Although the system is semi-automated, human intervention is limited to a few simple tasks to maintain the high throughput and consistent quality required for commercial application. In contrast to existing systems that fabricate custom heads that are assembled to pre-fabricated plastic bodies, our system seamlessly integrates 3D facial data with a predefined figurine body into a unique and continuous object that is fabricated as a single piece. The combination of state-of-the-art 3D capture, modeling, and printing that are the core of our system provide the flexibility to fabricate figurines whose complexity is only limited by the creativity of the designer.
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