Both the new and returning characters had their animation models designed by Floro Dery. Unlike the returning characters; which were based on their toy prototypes; the new characters were designed for animation first, which then became the basis for the toys. One notable exception was Ultra Magnus. Dery's original design for Ultra Magnus was discarded, but used instead for Orion Pax in Transformers: The Search for Alpha Trion (1985). Ultra Magnus's design was the based on an upgrade to Dialcone's Battle Convoy (the original mold for Optimus Prime), which combined with its new trailer (the car carrier) to become Powered Convoy. The character originally also used Powered Convoy's color scheme, as seen in animation for an early trailer. That was later changed to the final color scheme.

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