Were they cast in molds? I assume only so many types/characters were made and then hundreds made like each. Or?
The terracotta figures were manufactured both in workshops by government laborers and also by local craftsmen. The head, arms, legs and torsos were created separately and then assembled. Studies show that eight face moulds were most likely used, and then clay was added to provide individual facial features.[5] Once assembled, intricate features such as facial expressions were added. It is believed that their legs were made in much the same way that terracotta drainage pipes were manufactured at the time. This would make it an assembly line production, with specific parts manufactured and assembled after being fired, as opposed to crafting one solid piece of terracotta and subsequently firing it. In those days, each workshop was required to inscribe its name on items produced to ensure quality control. This has aided modern historians in verifying that workshops that once made tiles and other mundane items were commandeered to work on the terracotta army. Upon completion, the terracotta figures were placed in the pits in precise military formation according to rank and duty.
The terracotta figures are life-like and life-sized. They vary in height, uniform and hairstyle in accordance with rank. The colored lacquer finish, individual facial features, and actual weapons and armor from battle used in manufacturing these figures created a realistic appearance. The original weapons were stolen by robbers shortly after the creation of the army and the coloring has faded greatly. However, their existence serves as a testament to the amount of labor and skill involved in their construction. It also reveals the power the First Emperor possessed, enabling him to command such a monumental undertaking as this.
The figures vary in height (183–195 cm - 6ft–6ft 5in), according to their role, the tallest being the generals. The figures include strong warriors, chariots, horses, officials, acrobats, strongmen, and musicians. Current estimates are that in the three pits containing the Terracotta Army there were over 8,000 soldiers, 100 chariots with 400 horses and 300 cavalry horses, the majority of which are still buried in the pits.