"Being John Malkovich" nesting doll (© 1999 USA Films, © 2000 USA Home Entertainment) was one of our biggest projects. We produced 40,000 dolls in two months.
To meet the rigid time frame of our customer we modified the old doll-making technology with computer assisted design and fast printing equipment. The trickiest task for the project's success was to build a bridge between non-conformity of blank dolls from the cottage industry and the requirements for high speed precision printing.
Every carver has his own style and uses his own eye as a measuring instrument. Dolls from different masters taken apart rarely nest interchangeably with each other. But every doll of a 5 piece set must be painted and lacquered and put back where it belongs.
Fifty individual carvers from Polkovski Maidan supplied blank dolls for us making 5000 5 piece dolls a week. We managed to orchestrate all steps of production, so, every day, more than one thousand of finished Malkovich dolls were packed at our warehouse in St. Petersburg.
We are proud to say that the doll won an award from Premier magazine as the best promotional merchandise. It is available for sale as a part of Being John Malkovich Limited Edition Collector's Set (1999) at Amazon.com