Hi, I'm Dan

I currently lead product development at CORGI, bringing to life products and experiences that people love.

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The production process

• End-to-end product development
• Reverse engineering
• Tooling
• Production oversight

Originally released in the late 1960s, the Corgi 270 Aston Martin DB5 became one of the most iconic die-cast models ever produced.When the decision was made to reintroduce it, there was no usable tooling and no digital data. The original model had to be studied, understood, and rebuilt entirely from scratch.I was responsible for the end to end product development of the model, reverse engineering the original and leading the complete retooling process, while carefully preserving its proportions, mechanical features, and character.From the outset, I wanted this work to be documented. Not as marketing content, but as a record of how analogue thinking and modern manufacturing can coexist.Each component was developed individually, balancing historical accuracy with modern tolerances, repeatability, and production requirements.The film brings together moments from across the production process, offering a rare view into how a heritage model is manufactured today.The final model retains the mechanical features, proportions, and tactile qualities that defined the original, while meeting modern manufacturing, safety, and quality standards.

Production film

Overview

• Continuous Product Development
• Curated
• Scale
• Sequencing
• Collection Built

The Corgi Model Club reissues models from Corgi’s historical catalogue through a continuous monthly release schedule. This makes the programme one of the few product lines delivered through ongoing manufacture rather than one off reissues.


My roleI own the product line: defining release sequencing, directing reconstruction and tooling, coordinating licensors and suppliers, and ensuring each monthly release meets manufacturing, cost, and quality constraints.

65+

Releases to date

1 model a month

Release schedule

~3000

Active members

Reconstruction & development

Each release begins with reconstructing an original model, translating historical proportions, mechanisms, and character into modern tooling and manufacturing. Materials, tolerances, and finishes are adjusted while preserving the identity of the original.While the programme benefits from recurring patterns, certain releases demand deeper work due to mechanical complexity, licensing, or cultural significance.The 270 Aston Martin DB5 represents the deepest reconstruction to date with moving parts and complex mechanisms.

• View project

Operations & Delivery

Running a small batch heritage line requires ongoing coordination between licensing approvals, tooling partners, factories, and collectors. The value is delivered over time, as a continuous collection rather than through individual launches.The work balances heritage accuracy, manufacturability, and cost discipline within the constraints of monthly release sequencing and small batch production.Trade offs
• Heritage fidelity vs manufacturability
• Monthly cadence vs lead times
• Cost vs small batch production
• Licensing approvals vs release sequencing

Collection Behaviour

The programme is built around continuity and nostalgia rather than product features. Collectors build a catalogue over time, where the cumulative value of the collection exceeds that of any individual release.