How is Thomas and Friends made?

Answer 1

The train characters are models built to a 1:32 scale, known in the model railway world as "O" Scale. Because very small model trains are filmed moving in real time. It was filmed in production studio is the size of an aircraft hangar, and filled with a collection of more than 70 16-by-20-foot sets. To create the characters of Thomas, Henry, Percy, Gordon, and the gang, model-makers start with Marklin model train chassis and then modify the bodies to represent the various characters. Under a train's body shell lies the mechanism for moving the engine's eyes -- up, down, sideways, or 'round and 'round -- by radio control. In addition, there is a diaphragm pump and smoke unit to blow the specially formulated "smoke." Each character has its own basic face, which is first sculpted in clay. Then a rubber mold is made, and several copies are cast in a mixture of resin and auto-body filler. Each replica is reworked into different expressions, from which a final silicone casting is taken. The characters' faces are changed between shooting sequences and are held in place with nothing more sophisticated than double-sided adhesive tape. Thomas alone has more than 40 faces cast for him, while the other engines have five or six each.