I just started repainting two X-Wings to match Red 3 (Biggs) and Red 5 (Luke). Masking the areas for the red color took some effort, so I started wondering how could this be done in mass-production to get a consistent quality?

Any ideas on how the details are applied in production, e.g. (blood) stripes, cockpits?

My guess would be that they have prefabbed plastic masks that they drop the ship into and spray over to get what they need. That said, I'm pretty sure more people on the board here free hand most of the paint since masking on this scale is such a PITA.

Seconding either a prefab mask or a stamp.

My guess would be that they have prefabbed plastic masks that they drop the ship into and spray over to get what they need. That said, I'm pretty sure more people on the board here free hand most of the paint since masking on this scale is such a PITA.

Masking is always a PITA (gotta use that more), and as you say, on this scale it's even more problematic. Just about all the stuff I've painted has been by hand, little to no masking.

A while back I asked a friend who has a masters degree in sculpture how he though they did it. He said they most likely use a mold, and spray the paint on. I think the wash is done by hand, my CR90 has a finger print in the wash on an engine.

Also, according to a friend who worked as a project manager for KayBeeToys, the molds they use for the ships warp and wear out over time, so they have to make new ones. That could be a reason some of the reprints seem to take so long to ship.

My guess would be that they have prefabbed plastic masks that they drop the ship into and spray over to get what they need. That said, I'm pretty sure more people on the board here free hand most of the paint since masking on this scale is such a PITA.

The prefab idea sounds very reasonable, great!

Masking is always a PITA (gotta use that more), and as you say, on this scale it's even more problematic. Just about all the stuff I've painted has been by hand, little to no masking.

You guys were absolutely right on the PITA-Masking-Situation !

I did the red color today and after peeling off the tape the result was not as crispy and defined as envisioned. I should have skipped that tedious step and just free-handing it like I did on my Zee-95ers before.

I am fairly certain that they use brushes!

I think the wash is done by hand, my CR90 has a finger print in the wash on an engine.

Mine had a finger print as well, and since I'm a detail freak was kinda upset, so my wife suggested to clean it with Windex and just re-apply the wash on that area, to my surprise Windex removed the wash without affecting the paint below, then re-applied the wash, the black one from GW which I can't remember the name now and the finger print problem is gone.

Just as a side note, go easy with the Windex, I'm sure if you really damp the model or apply to much pressure the paint will be damaged

12 year old Chinese kids, working in a sweat shop for minimum wage, have very steady hands... due to their casual martial arts training.