Hey, I know EVERYTHING there is to know about toy design, and I learned it all on fan forums! Plastic comes from petroleum, which we get from...petrorabbits, I think...and then that gets cast into steel molds made from a resin prototype which was assembled by elves working at the North Pole, and they do it free so any cost cutting is entirely because Hasbro hates fans, and the product should always be whatever I was thinking of when fabulous secret powers were revealed to me the day I held aloft...no, wait, that figure's not out yet, doesn't count. And plasticizer can't melt cardboard.
I should probably admit that due to Transformers not normally impacting my eating/medical situations, I see the whole thing as entertainment and only tend to pay attention during the fun parts. I may have missed a step or two. Whatever. I still am waiting for those Combaticon preorders to go live.