Dear King's Man,
While Andy may wish to correct me, I do not think his costs are as high as you think. I believe most, if not all, of the KCS figures are slight variations of the castings used for the Del Prado Cavalry of the Napoleonic Wars series. If you go to the Del Prado USA site (
www.delpradousa.com), compare the following from that series:
DEL-NC48 to KCS076 (arm w/ gun moved)
DEL-NC50 to KCS074 (head rotated slightly)
DEL-NC54 to KCS068 (head rotated slightly, straps more distinct)
DEL-NC59 to KCS067 (head rotated slightly)
DEL-NC82 to KCS073 (sword arm moved so sword resting on shoulder)
You will also see that NA25 is DEL-NC03 with the gun arm lowered but painted to a far higher standard.
If I am correct, then Del Prado paid for the sculpting and production of molds when they ordered millions of figures from K&C. K&C simply cast more figures where the cost is just the labor and alloy, moved an arm or head, added more detail like distinct straps, and painted them in a different uniform to a much higher standard. Andy stated KCS was painted at K&C's own "master painting studio" in China, not a factory. Andy is paying these employees a salary irregardless of whether they painting or just sitting around, so it makes perfect business sense for K&C to have them paint figures for sale when there are no masters or samples that need to be painted. Andy is continuing the long tradition of many "toy soldier" manufacturers in slightly altering existing castings and painting them in a different uniform to create new products. With this type of business model, K&C can make money on very small production runs.
P.S. While writing my post, Fishead19690 posted his response.