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Once the graphics are finalized, manufacturers move to the creation of the tin boxes themselves. The process involves cutting and shaping sheets of steel, which are coated with a layer of tin to prevent rusting and ensure durability. The pieces are then pressed into shape and assembled—usually featuring a hinged lid and a sturdy handle, reminiscent of the lunch boxes popularized in the mid-20th century.
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The process of creating these costumes involves a blend of traditional sewing techniques and innovative design. Suppliers often employ methods to create a three-dimensional effect, ensuring that the finished product looks as much like an actual tin can as possible. This involves strategic pleating, layering, and embellishment. Additionally, costumes are tailored for various age groups, ranging from children’s sizes to adult fits, allowing families to participate in themed celebrations together.
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