When I was with Forgeworld back in '99, it was not quite at the start of it all, but it was the start of the second "version". Previously FW had had one or two small bust models and not a lot else had been done and things were effectively going nowhere. This was when Tony Cottrell was given the reins and the catalogue of available models really took off. Most of the new range was made up of Tony's conversion parts of Imperial guard tank turrets and other bits and pieces. All of these were hand made masters from base plastic parts with additional funky bits made from tubes and plastic card, etc. The biggest problem that we had with any of these was small bubbles in the casting process. Sometimes we would get a really bad cast back due to humidity during casting (water in the resin makes it foam), but this is why we had QC at the casters as well as QC at the receiving warehouse (that is, the broom closet that I ran.... seriously, it was tiny - the entire FW staff was 4 and that included our accountant). The first big model that came along (aside from the large scale marine figures) was the Baneblade and that was cast from a hand built master too, it took a lot of back and forth to get that one right. That arrived towards the latter part of '99 as it was being advertised at Games Day that year. There had always been plans to make more and more large scale things as people really wanted to get the Thunderhawk back up and running now that the metal kits (which was never designed to be sold as a kit) had pretty much dried up. Titans were very much on the list too, but the tech for producing them wasn't really up to scratch yet, they would have been made in a lot more smaller parts which would just mean more drilling, pinning and general weakness of the final result.