I can only speak from my personal experience so take it for what it's worth. But in my time developing product for EFX or Sideshow there was never an instance where we were forced to purposely make anything less accurate than the film equivalent.
In my opinion, any mass produced prop replica that turns out different from the filming prop can be boiled down to a handful of factors.
Here are some off the cuff but I'm sure if I thought about it longer I could list more.
From a 'discretional' standpoint:
- The amount of purposeful idealization added because that was the preferred personal taste of the person or team in charge of product development. In other words, how accurate the developer would
WANT to make it regardless of any practical obstacles.
- The overall ability of the person or team in charge of product development based on a combo of their training, skills, experience, knowledge of the subject matter, and of course natural talent. In other words, how accurate the developer is
ABLE to make it regardless of any practical obstacles.
- These two aspects above massively influence the judgement for all the big and little decisions throughout the entire product cycle from development to production and all these following points.
From a 'practical' standpoint:
- Purposefully or strategically choosing idealizations that dramatically reduce production costs or aspects that are too difficult for a factory production team to replicate with consistency or at times even at all.
- Purposefully choosing idealizations that would please the largest amount of your audience since different collectors prefer it different ways.
- Purposefully choosing idealizations that improve the craftsmanship or durability to meet customer's expectations. For example even though I might personally prefer a flimsy totally screen accurate filming prop that might fall apart in my hands if I hold it the wrong way or take natural damage from basic handling, in my experience most customers don't prefer that. lol
- Determining a stopping point in development in terms of deciding this is as close that the factory can get to matching your prototype and accepting those limitations/idealizations.
From a 'factors outside of your control' standpoint:
- Factories making changes during the production run without consent or consulting the client that differ from the final approved prototype knowing there is little recourse from the client after the fact.
So if you imagine a sliding scale with 'idealized props' on one end, and 'warts and all accurate filming prop' on the other, my personal taste is about as far to the warts and all side as you can possibly get and it's totally reflected in my personal projects.
So because of that I try to bring those sensibilities to bear on any project I'm involved in licensed or otherwise as much as I can within the requirements of the project.
For me making licensed props is a painful balancing act riddled with compromises I wouldn't want to make for myself so you do the best you can at all the steps along the way so that the item that comes out on the other end is as close as you can get with all the factors weighing against you.
my .02c
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