Inside the 1-XM Workshop: How We Cast Each X-Model by Hand

At 1-XM, we do not just design collectibles — we build them. Every X-Model is 100% in-house: from concept sketches and 3D modeling through mold making, resin casting, LED integration, and final quality assurance. No overseas factories. No outsourcing. Just a team of designers, engineers, and craftspeople working under the same roof to bring each piece to life.

This level of vertical integration is rare in the designer collectible industry. According to Market Intelo, the designer toy market reached $1.8 billion in 2025 and is projected to hit $3.9 billion by 2034 at a 10.2% CAGR. Yet the majority of production in this space is still outsourced to contract manufacturers. 1-XM’s decision to keep everything in-house reflects a commitment to quality, control, and craftsmanship that directly impacts every piece that reaches your shelf.

Step 1: From Sketch to 3D Model

Every X-Model begins as a hand-drawn sketch. Our design team explores form, proportion, and aesthetic direction on paper before moving to digital. Once a concept is selected, it is refined in 3D modeling software, where every angle is optimized for both visual impact and manufacturability.

Key considerations at this stage include:

• LED cavity design — the internal space for the LED array is integrated into the 3D model, not added as an afterthought
• Cable routing — USB-C power delivery paths are planned within the sculptural form
• Structural integrity — wall thickness, support geometry, and stress points are analyzed to ensure durability
• Mold feasibility — the model is optimized for silicone mold creation, ensuring every detail will transfer faithfully

This is the stage where generative LED collectibles diverge from traditional static figures. The LED system is designed as an integral part of the object, not a module that is squeezed in later.

Step 2: Mold Making — The Art of Precision

Once the 3D model is finalized, we create precision silicone molds. This is a craft in its own right — the mold must capture every microscopic detail of the original while allowing clean demolding and maintaining its shape through repeated casting cycles.

Silicone molds for resin casting typically yield 25–100 castings before the material degrades and the mold needs replacement (Wikipedia — Resin Casting). This inherent limitation is a feature, not a bug — it naturally caps production runs and ensures that every piece comes from a fresh, high-quality mold. It is also why limited edition runs in the designer collectible space are typically capped at 500–5,000 units (Market Intelo), and why each piece in those runs carries a premium.

Step 3: Hand Casting with Premium Cast Resin

Each X-Model is hand-poured using premium polyurethane casting resin — the same material used in museum-grade reproductions and high-end designer toys. The process is deliberately slow and manual:

1. Liquid resin is mixed with a curing agent according to precise ratios
2. The mixture is poured into the silicone mold in a controlled manner to minimize air entrapment
3. The mold is manipulated by hand to release any trapped air bubbles
4. The resin cures at room temperature via exothermic polymerization
5. The piece is carefully demolded — a process that requires skill to avoid damaging both the casting and the mold

This is fundamentally different from injection molding, where molten plastic is forced into a steel mold under high pressure at industrial scale. Injection molding is fast, cheap per unit, and produces identical parts — but it cannot match the surface quality, detail capture, and hand-finished character of cast resin. According to SyBridge Technologies, polyurethane casting resin “combines the strength of injection-molded parts with high-quality surface finishes and chemical and abrasion resistance” — delivering the best of both worlds.

Step 4: Hand Finishing

Once demolded, each piece enters the finishing stage — the most labor-intensive part of the process:

• Sanding — mold lines, flash, and any surface imperfections are removed by hand using progressively finer grits
• Polishing — the surface is brought to its final sheen, enhancing the appearance of the cast resin
• Inspection — every surface is examined under controlled lighting; any piece that does not meet standards is rejected

No two pieces emerge from hand finishing perfectly identical — each carries subtle variations that are the mark of human craftsmanship. For collectors, this is part of the appeal. Unlike mass-produced items where every unit is interchangeable, each hand-finished X-Model has its own character.

Step 5: LED Integration and Testing

The RGBW LED array is hand-soldered and integrated into each unit. This is where the physical form meets the digital intelligence that defines it as a living object.

Our RGBW LEDs are algorithm-driven, meaning the controller runs generative code rather than a fixed light program. The algorithm determines:

• Color transitions and blending
• Timing and sequencing curves
• Brightness modulation and pulsing
• Randomization parameters that ensure no two units produce the same pattern

For more on the technology that powers these patterns, see our deep dive: The Art of Light: How Generative LED Patterns Define Modern Collectibles.

Step 6: Quality Assurance — The 20-Minute Burn-In

Before any X-Model ships, it undergoes a rigorous quality assurance process:

• Visual inspection — finish quality, surface defects, mold integrity
• LED functionality — all channels tested for color accuracy and brightness
• Pattern verification — the generative algorithm is run through a full sequence to verify correct operation
• 20-minute burn-in test — the unit runs continuously for 20 minutes to confirm stability, heat management, and consistent performance
• Structural check — the casting is examined for cracks, weak spots, or assembly issues

Only pieces that pass all stages of QA are packed and shipped. This level of testing is only possible because production is in-house — we do not have to rely on a factory’s QA reports or trust that overseas quality standards match our own.

Step 7: Packing and Shipping

Each X-Model is carefully packed with its custom stand and USB-C cable. Packaging is designed to protect the piece during transit while maintaining the premium unboxing experience that designer collectible buyers expect.

Why In-House Production Matters

The decision to keep production in-house is not just about quality control — it shapes everything about the product and the collector experience:

According to Market Intelo, 67.3% of designer toy buyers collect for personal enjoyment rather than investment — and a key driver of that enjoyment is knowing the story behind the piece. In-house production allows us to tell that story authentically.

Frequently Asked Questions

Where are 1-XM collectibles made?

Every X-Model is made in-house at the 1-XM workshop. We do not outsource to overseas factories. Everything — from design to casting to LED integration to final QA — happens under one roof.

How long does it take to make a designer collectible?

A single production batch takes several days. Custom projects through the Custom Lab have a turnaround of 2–6 weeks.

How are the LED patterns programmed?

The patterns are algorithm-driven, not manually sequenced. Each unit’s controller runs generative code that produces unique, non-repeating light patterns. No two X-Models share the same light signature.

Are 1-XM collectibles tested before shipping?

Yes. Every unit undergoes a full visual inspection, LED functionality test, pattern verification, and 20-minute burn-in test before it ships.

See the Full Collection

Every X-Model you see in our catalog — from Mini blind boxes to the Flux Series 001 flagship — passes through this same workshop, built by the same team, using the same process and materials. Explore the full X-Model collection →

Want something built just for you? Start a Custom Lab project →

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Further Reading:

• First Look: Flux Series 001 — Limited Edition of 100
• The Art of Light: How Generative LED Patterns Define Modern Collectibles
• Understanding Cast Resin, RGBW LEDs, and Premium Collectible Materials
• The Complete Guide to Starting Your Designer Collectible Collection