Action Figure Design Frustrations: The 10-Year Journey to Zip Gal

After nearly a decade of development, Zip Gal is officially coming in 2026. This video shares the full story behind the world’s first 3D-printable articulated action figure system using zip ties—from early proof-of-concept builds on a Tronxy Cyp 802, to anatomical challenges at 1/12th scale, to the mindset shift that finally made release possible.

The Origin Story

This is Zip Guy. The world’s first 3D printable articulated action figure that uses zip ties for joints.

Almost 10 years ago, I started a journey to create my own line of action figures. But with limited resources, limited knowledge, and honestly no idea what I was doing, I had to rely on some very unconventional solutions.

And somehow, the zip ties worked.

Why Zip Ties?

When I started designing my Zip Guy action figures, I wasn’t really focused on anatomy at all. What I did have was this weird idea I wanted to test immediately.

Ball-jointed dolls use elastic bands for articulation. So I thought, why not use zip ties as action figure joints? They’re made of nylon. They’re tough, flexible, and self-lubricating.

Every time I learned something new, I started seeing more flaws that needed fixing. But the technical problems weren’t the only thing slowing me down.

The Piracy Problem

A few years ago, some followers told me there was a private online group sharing paid 3D models from different creators without permission. And unfortunately, some of my files were already being distributed there.

At the time, I took that really hard.

So instead, I focused on my male base figures and pushed Zip Gal further and further into the background.

Zip Gal is Finally Coming

But after all these years of development, testing, and refinement, I’m finally ready.

Zip Gal is officially coming in 2026.

This time, for real. It’s been almost a decade in the making, but the wait is almost over.

Function-First Design Philosophy

Throughout this entire journey, I’ve maintained a function-first design philosophy. Every decision was made with accessibility in mind:

• Engineering articulated joints with nylon zip ties — No screws, no ball joints, just simple hardware store zip ties
• Scaling considerations for Ender 3-class printers — Designed to print on entry-level FDM printers that most people already own
• 1/12th scale by default — Small enough to print quickly, large enough to detail
• Scalable to 1/6 — Want a bigger figure? Just scale it up in your slicer

3D Printing as Legitimate Manufacturing

Anyway, speaking of creating, one of the weird things about being a content creator is that opportunities start showing up outside your usual niche.

Most of them aren’t paid collaborations or sponsorships, but sometimes they’re still interesting enough that you just want to check them out.

Like these guys from Make.com. They asked if they could send me this 3D printed RC Formula 1 racer.

I mean, 3D printed RC cars have been around for a while now, but seeing something like this come packaged in a box like an actual consumer product, and treating 3D printing as a legitimate manufacturing method for this kind of toy, is kind of freaking amazing.

This is proof that 3D printing isn’t just for prototyping anymore—it can be a real manufacturing method for consumer toys.

What’s Next?

With Zip Gal finally ready for release in 2026, I’m excited to see what the community creates with this new system.

The same innovative zip-tie articulation that made Zip Guy possible is now available for female characters, opening up entirely new possibilities for custom builds.

Live Poll: Which Character Next?

I want to hear from you: Which Zip Gal character should I design next?

Drop your ideas in the comments on YouTube or tag me on Instagram @3DZipGuy. I read every suggestion.

Resources & Links

The Bottom Line

Nearly 10 years. Countless prototypes. More failed prints than I care to admit. And through it all, one simple idea: zip ties can be action figure joints.

It sounded crazy at the time. It still sounds a little crazy now.

But it works.

And in 2026, Zip Gal finally joins the family.

Disclaimer: Some links above are affiliate links—I may earn a small commission at no extra cost to you. This supports channel development and keeps tutorials free. All 3D models are for personal use unless explicitly licensed for commercial use.