Star Wars design director at Hasbro, Steve Evans, discusses the revolutionary new process that’s literally changing the face of Hasbro’s action figures….

When Hasbro‘s Star Wars: The Black Series line arrived in 2013, it was a game-changer. Highly-detailed, highly-articulated figures in a 6-inch scale — it was something fans had wanted for years. And the line has been a joy, garnering critical acclaim while delivering everyone from X-wing pilot Luke Skywalker to fan favorites like Hera Syndulla of Star Wars Rebels. A key to the line’s success, however, is that throughout the Black Series’ run, Hasbro has always pushed forward and experimented. Black Series has introduced vehicles and creatures. Employed vintage-style cardbacks for Star Wars‘ 40th anniversary. Remade Darth Vader from the ground-up for one of the best figures of the Sith Lord ever produced.

But Hasbro’s latest experiment may be its most revolutionary: “Photo Real,” a new paint-application process that has led to stunning likenesses on the new crop of Black Series figures, including Rey, Captain Rex, DJ, and the upcoming Grand Moff Tarkin.

The problems to be solved, according to Evans, were, “How do we do faces A) better and more realistic to the characters that we’re seeing up on the screen and B) more consistently so that we can remove the variances that you get in traditional paint applications?” Enter Photo Real.

Read the full article with commentary from Steve Evans at StarWars.com now.