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How PC Army Men 2D games were made

Army Men 2.5D games: Step by Step

The first Army Men games, Army Men (1998), Army Men II (1999), Army Men: Toys in Space (1999), Army Men: World War (1999, PC version), and Army Men: Air Tactics (2000) were developed by The 3DO Company during the late ’90s. These titles were created for PC, though some would later be adapted to consoles.

At the time, 3DO’s internal development relied heavily on a mix of 3D modeling tools, custom engines, and asset pipelines tailored for low-end consumer hardware. Each game was built with a relatively short development cycle (often under a year) requiring assets reuse, modular design, and a streamlined production process.

The visual style combined pre-rendered 3D elements (created in 3D Studio Max software) with in-game sprites and textures, carefully optimized to run within the memory and performance constraints of computers of the time. Meanwhile, cutscenes and promotional material often featured higher-quality renders that were directly representative of in-game graphics.

The combination of these production methods, rapid iteration, and the particular creative direction of 3DO’s art team gave the early Army Men titles their distinct aesthetic… halfway between miniature toy realism and stylized video game worlds.

1. Concept and Scripting

Designers began with a concept document defining the environments, enemies, mission objectives, and available weapons.

These documents were usually very functional, focusing on mechanics before narrative (although Toys in Space and Air Tactics had more elaborate storylines).

The narrative script and dialogues were written in parallel with level planning so the story wouldn’t interfere with technical limitations.

2. Creation of 3D Assets

Models of soldiers, vehicles, and environments were made in 3D Studio Max.

Sarge 3D model from Army Men Toys in Space
Sarge 3D model from Army Men Toys in Space

Although the final game used highly simplified sprites, high-quality 3D model versions were created for marketing renders and cutscenes.

The models were “baked” into sprites or textures, trimming polygons and reducing color palettes to fit within RAM and VRAM limits at the time.

It’s important to note that the 2.5D Army Men games were developed exclusively for PC; console versions used different adaptations of the game engine and design approach.

So… how?

2.1 – 3D Modeling and Texturing

The visual production of the early Army Men titles was a meticulous and multi-step process that combined 3D modeling, detailed texturing, and careful sprite rendering. Development teams began by designing each character, vehicle, and object as a fully realized 3D model in 3D Studio Max. These models were built with more geometric detail than the final games would ever display, ensuring that the rendered sprites would look crisp and convincing even at the relatively low resolutions of late 1990s PC games.

Textures were then painted by hand or derived from scanned materials, giving plastic surfaces their distinctive molded look. Special care was taken to simulate the subtle light diffusion and shading characteristics of plastic, which gave the Army Men their iconic, toy-like presence. Vehicles, buildings, and environmental props followed the same pipeline, often modeled with exaggerated proportions to read clearly from the game’s fixed viewpoint.

  • The process began in 3D Studio Max, where artists modeled soldiers, vehicles, weapons, and environmental props in full 3D.
  • Although the game ultimately used sprites (2D images), the models were initially built with full geometry, high-resolution textures, and realistic proportions for marketing renders and cutscenes.
  • Textures were painted by hand or generated from photographic references, then downscaled and palette-limited to fit the technical constraints of the game engine (often 256 colors per set).
  • Each model was rigged with basic skeletons in Max’s “Biped” system for posing, not for real-time animation. All movement was baked into pre-rendered sequences.

Once modeling and texturing were complete, the development team moved to the rendering stage. Instead of importing the 3D models directly into the game engine, they were pre-rendered into 2D sprites. This technique allowed for a higher level of visual fidelity than real-time 3D of the era could achieve on average home PCs. Animations (such as walking, firing, or rotating turrets) were rendered frame-by-frame in 3D Studio Max, then exported as sprite sheets to be used in-game. Special effects like muzzle flashes, smoke, and explosions were often created as separate rendered sequences and composited on top of the base sprites.

2.2 – Environment Creation

The environments followed a similar principle. Terrain tiles, buildings, and interactive objects were modeled and rendered in segments, allowing designers to piece together maps within the game editor. Lighting was baked into these renders, giving the illusion of complex shading without taxing the PC’s hardware.

The gameplay itself was presented from a fixed isometric camera perspective, tilted at roughly a 45-degree angle. This viewpoint was carefully chosen to maximize the clarity of the battlefield while retaining a sense of three-dimensional depth. From this angle, players could easily distinguish elevation, obstacles, and the orientation of units. It also allowed artists to control exactly how models were rendered, ensuring consistent proportions and lighting across the entire game world.

The combination of high-quality pre-rendered graphics, baked lighting, and the stable isometric viewpoint gave the early Army Men games their distinctive “miniature war” aesthetic, striking a balance between technical limitations and the highly artistic ambition of 3DO’s Trip Hawkins.

  • Game environments were also modeled in 3D, but separated into terrain layers and static props.
  • Terrain tiles were rendered at fixed angles to match the isometric view, then stitched together in the in-house map editor.
  • Static objects (buildings, trees, fortifications) were rendered as isometric sprites with multiple damage states where applicable (e.g., intact, damaged, destroyed).
2.3 – Rendering Sprites
  • The 3D models were placed in a rendering scene with lighting and camera settings that matched the game’s perspective.
  • Soldiers and vehicles were rendered in 32 or 64 different angles, depending on their importance.
  • Animations (walking, shooting, reloading, turning) were rendered frame-by-frame into sprite sheets.
  • Each frame was then processed to remove the background, optimize colors, and align pivot points so the engine could rotate and move them smoothly.

In the image below we can see the “Tile Cam,” or sprite capture position camera. A graphic that 3DO developers always kept in mind to know the angle of each of the multiple images they had to capture of each 3D model, to obtain the 360-degree motion effect of soldiers, vehicles, etc., in addition to each set of images carrying a weapon and the like. The yellow arrow, in addition to functioning as a clock hand indicating the angle of capture, also marks the height at which the camera should be positioned. The object/model goes in the center of the graphic.

2.4 – Special Effects
  • Explosions, muzzle flashes, smoke, and fire were usually hand-drawn frame-by-frame in a pixel art program to achieve a stylized look and keep file sizes small.
  • Some effects, like shadows and ambient lighting, were faked by rendering a semi-transparent dark shape beneath the units.
  • Transparent effects (glass, water, energy shields) were simulated with dithered patterns instead of true alpha blending, to ensure performance on lower-end hardware.
2.5 – Movement and Animation Systems
  • Despite being based on 3D models, all gameplay movement was sprite-based. Each unit had pre-rendered frames for each movement direction.
  • The engine swapped frames quickly to simulate animation, while changing the sprite set to match the direction of travel.
  • Rotation was not continuous but snapped between the pre-rendered angles, giving the characteristic “stepped” turning look.
  • Collision detection was based on simplified bounding boxes rather than the full shape of the sprite.
2.6 – Integration into the Engine
  • All assets (units, terrain, effects) were packed into proprietary resource files.
  • The engine combined terrain tiles and object sprites in real-time, overlaying animated units and effects according to their Z-order (depth).
  • Lighting changes were simulated with palette swaps, allowing entire environments to shift from day to night without rerendering the assets.

3. Maps and Levels

Environments were built using an in-house proprietary editor designed specifically for the Army Men engine.

This editor allowed placement of terrain, static objects, and “event points” (enemy spawns, mission scripts, sound triggers).

Maps were generally small to keep loading times low and were often connected through transition screens or cutscenes.

4. Programming and Engine

The Army Men engine was an evolution of a framework that 3DO had already used in other strategy and action games.

It supported:
  • Pseudo-3D sprites and pre-rendered rotations.
  • Multiple terrain layers to simulate elevation.
  • Basic AI scripting and enemy behavior.
  • The code was primarily written in C/C++, with auxiliary tools in Visual Basic for resource conversion and packaging.
4.1 – How camera, pathfinding, and depth sorting worked

Since that’s what made Army Men’s isometric view feel dynamic despite being built entirely from static sprites. That part connects directly to how the movement system was implemented.

The isometric camera itself was fixed in angle but could pan across the battlefield. Camera movement was tied to mouse edges or keyboard input, and it followed a smooth scrolling pattern to maintain player orientation. Since the camera never rotated, all sprites could be pre-rendered from the same set of angles, greatly reducing memory use and production time.

Pathfinding relied heavily on an A* (A-Star) algorithm adapted to the isometric grid. The system calculated optimal routes while accounting for terrain type, impassable objects, and unit collision. Because maps often featured elevation changes (ramps, cliffs, and bridges) the pathfinding system also factored in “height layers,” preventing units from attempting impossible routes. This was especially important for vehicles, which had stricter movement constraints than infantry.

Depth sorting (deciding which objects should appear in front of or behind others) was handled through a “Y-sorting” system. The engine drew objects in order of their Y-coordinate in world space, meaning that units lower on the screen (closer to the player’s viewpoint) would be rendered on top of those further back. This simple yet effective technique ensured consistent layering without the need for real-time 3D z-buffer calculations.

4.2 – Movement, Interaction, and Technical Implementation in the Isometric Engine

The fixed isometric perspective of the early Army Men titles was not just a visual choice.. it directly influenced how movement, interaction, and gameplay logic were implemented.

Unit movement was handled on a 2D coordinate grid that corresponded to the isometric map’s tile layout. Each tile represented a fixed unit of space, but because the camera was angled, the game had to apply a transformation to convert “world” coordinates into their isometric screen positions. This meant that while players saw units moving diagonally across the battlefield, the game internally calculated their positions in standard X-Y Cartesian space.

Interaction with the environment followed a “selection → command → execution” model. When the player selected a unit, the game temporarily highlighted its sprite and displayed its selection circle, a 2D ring projected onto the ground plane. Issuing a movement or attack order triggered an internal check: the game verified whether the destination tile was valid, whether the target could be reached, and whether line-of-sight was available (a simplified visibility check rather than true 3D ray tracing).

Together, these systems created a smooth and intuitive gameplay experience despite the limitations of late-90s PC hardware. The isometric rendering allowed for highly detailed graphics, while the underlying grid-based logic kept gameplay predictable, readable, and strategically satisfying.

5. Testing and Optimization

Testing was intensive because different PC systems required different optimizations to work. Back then, consoles were a single, unified system, but on PC, there are multiple different systems that require tweaking the game for proper universal operation. At that time, the game that was launched usually was the final version, with no DLC to fix the game post-launch. Although patches did exist, usually just one. Everything was always released in physical format…

On consoles, animation frames, polygonal 3D objects and texture details were reduced, and sometimes entire environmental elements were removed. But in this 2.5D games, usually was a matter of programming tweaking and fixing.

Testers reported bugs using printed screenshots (yes, on paper) with handwritten annotations.

The Making Of: Army Men – RetroGamer magazine. May 16, 2019. By Hareth Al Bustani

Exclusive interview with Trip Hawkins and Keith Bullen

During the mid-to-late 1990s, as video games began branching out beyond traditional genres, a surprisingly simple idea sparked the birth of one of gaming’s most memorable franchises. That spark was to bring the iconic green plastic toy soldiers (the Army Men) to digital life. What followed was a mix of action, strategy, and tongue-in-cheek satire that would grow into a universe of its own: the early foundations of what we now call the Toyverse.

The project emerged from The 3DO Company, founded by industry pioneer Trip Hawkins, who had already changed gaming history with Electronic Arts. At that time, 3DO was primarily focused on software development and searching for its next big concept… something that could blend strategy, humor, and accessibility. The result went far beyond expectation, shaping not just a game, but a world of plastic warfare and nostalgic imagination.

Origins of the Idea

It all began in 1996, when Keith Bullen, an art designer from Electronic Arts, was hired by 3DO to direct the visuals for a new project, then tentatively called War Sports. The goal was to create something in the spirit of Return Fire, 3DO’s popular vehicular shooter, but with stronger squad-based mechanics. Marketing wanted an “E for Everyone” rating, an idea ironically tied to the ESRB system that Trip Hawkins himself had helped establish.

“I remember various marketing meetings when ideas like green blood and making the soldiers robots were brought up as ways to get the game a friendly rating. I didn’t like any of these ideas.” – Keith recalls

Army Men Plastic Soldiers
Army Men Plastic Soldiers

Months passed without a clear direction, until Bullen had a eureka moment. He thought back to his childhood days, setting up tiny armies in the backyard and taking turns throwing rocks with his brother to knock them down. That memory (of creativity, chaos, and fun) became the emotional core of Army Men.

The toy soldiers had long been a universal symbol of imagination. From the Louis Marx playsets of the 1950s to Toy Story in 1995, these little green figures had stood the test of time. By centering the game around them, Bullen found a way to capture both nostalgia and originality, something fun for players who wanted a break from the gritty realism and machismo of other war games.

Army Men PC
Army Men PC (1998)

Building the Plastic World

Once the toy soldier idea took hold, Keith’s role evolved from art director to lead designer.

“Once the soldiers became plastic, we had to come up with a universe with real terrains and plastic soldiers,” he says. “We wanted the world to feel serious to the Army Men characters’ point of view but fun and nostalgic for the player.”

The team paid careful attention to the way plastic behaved in real life, how light hit its glossy surface, how it bent, shattered, and melted.

Green Army Men flamethrower

“We paid close attention to the physics in the animations. It was very important to me that the plastic pieces reacted to the world as if they were made of the same light plastic as the original figures.”

But turning that idea into a finished product wasn’t easy. The small team of six soon grew to more than ten as Bullen became creative director.

“It was very challenging convincing the team to adopt my new gameplay ideas… It took several months to finally get everyone on board.”

Executives were another obstacle. Early pitches for Army Men were dismissed as childish, “too young” some said. RTS fans, they argued, wouldn’t take seriously a game about toys. Yet Bullen persisted, finding clever ways to win people over.

Green Plastic Soldier
The “bought” generic soldier 3D model

“I then bought a 3D model of a generic Army Man and brought in some classic toy green and tan Army Men to use as pose references,” he remembers.
“For several weeks, many people from every department in the company would stop to discuss the posed 3D model… Soon after, the momentum switched from the product being perceived as too juvenile to being an awesome nostalgic experience.”

Sarge with rolled up sleeves, a modified version of the original 3D model

That was the turning point. Nostalgia had done its job.

From the Backyard to the Battlefield

The next challenge was translating the tactile world of toy soldiers into an interactive one. The developers recreated classic units like riflemen and bazooka troopers, while experimenting with how plastic would melt or break apart.

“We destroyed many plastic Army Men in the 3DO parking lot for the sake of realistic plastic physics,” Keith admits.
“The enhanced fear of fire when you are made of plastic was a theme we relied on throughout the series.”

To tie everything together, Army Men adopted a satirical tone. The game opened with a mock newsreel showing the totalitarian Tans preparing to invade the Greens.

Army Men News reel Introduction
Plastro from Army Men
The Mussolini Tan leader

“We watched many hours of authentic old reels… The Tan leader gesturing like Mussolini was one of my favourite segments.”

Originally planned as a real-time strategy game, Army Men evolved into something more direct and personal. Players would take control of Sarge, a Green Army hero.

“I’ve always preferred arcade-like action games over strategy games,” says Keith.
“So I redesigned the game around the central character of Sarge… as in games like Ikari Warriors.”

The final product blended tactical movement with fast-paced action.

“The gameplay became more about tactics, rather than strategy,” Bullen notes, crediting Crusader: No Remorse as an influence.

Trip Hawkins’ Perspective

One of the concept’s earliest champions was 3DO founder Trip Hawkins himself.

“Toy soldiers were my dominant play pattern as a child and I’d always invented strong storylines and adventures around them,” he says.
“Besides all the World War soldiers, I had Swoppets from the Wars Of The Roses, Roman centurions, and others – including cowboys, of course.”

Hawkins immediately recognized the blend of nostalgia, humor, and design potential behind Army Men.

“It inspired me to do something more central with humour in the genre and a stronger narrative.”

To him, the plastic theme wasn’t just an aesthetic choice: it was a creative platform.

“We were focused on the US market… nobody cared about them, because they’d not grown up with those toys.”

Despite the game’s playful tone, Hawkins insisted that warfare and destruction were essential to the experience.

“Creatively, we also wanted to have fun repeating some of the famous play patterns from childhood… It allowed us to cast our villains with a bit of sadism, that is still funny because… they’re just toys.”

Colonel Grimm and Sarge from Army Men
Colonel Grimm with Sarge

A Legacy Beyond Plastic

The development cycle lasted just over a year, despite several restarts. Once the formula clicked, Hawkins knew they had something special.

“This is what we live for in game development and publishing… to do something we really believe in and love.”

Across three themed terrains (desert, alpine, and swamp) Army Men culminated in a memorable twist: Sarge crossing into the Real World, a scene that would directly lead into Army Men II. The franchise quickly exploded, selling over 7 million copies across every major platform and generating more than $300 million in revenue.

The Greenville News
The Greenville News 01/29/1998

Looking back, Bullen reflects on the impact of that first title:

“I never would have imagined that it would spawn 23 sequels and spin-offs… My goal was to create a game that I would want to play and not a clone of a game I had played before.”

The Green Star
The Green Star 01/29/1998

Indeed, Army Men defied easy classification. It was part shooter, part strategy, part parody… a digital sandbox that reimagined childhood battles through the eyes of living toys. Beneath the surface, it captured something universal: the creative spirit of play itself.

From Sarge’s Heroes to the ever-expanding Toyverse, the legacy of those little plastic soldiers continues to march on.

Army Men PC inside
Sources for this article:

Original source: Retro Gamer (2019), “The Making Of: Army Men” by Hareth Al Bustani.
https://www.pressreader.com/uk/retro-gamer/20190516/281672551382117
Edited and adapted for armymen.com.ar