The 2002 revival of He-Man and the Masters of the Universe had much excitement surrounding it. One key aspect were the Four Horsemen (who would go on to sculpt and design the Classics line as well).
In ToyFare #54 the Four Horsemen (Eric ‘Cornboy’ Mayse, Chris Dahlberg, Jim Preziosi and Eric Treadaway) are interviewed on their approach to the world of Eternia and its characters.
They discuss about their meet up with Mattel, and how they worked for two years on the toyline prior to Mattel’s official announcement, their new Powersword design, and He-Man’s changing hair style thanks to focus groups.
There is even a mention, that how Skeletor’s Havoc Staff was going to have the ram skull-head as a pop-up function. That harkens back to early concept art by Mark Taylor, interestingly.
One curious thing to note is their initial idea to make Teela younger companion to He-Man. Their example is Batgirl to Batman from the 1992/1997 Animated adventures. But that Mattel wanted to keep Teela as love-interest, so she was made the same age as Prince Adam (this sadly was not fully played up in the cartoon by Mike Young Productions).
Huge thanks to Matthew Duch from Legends of Grayskull podcast for scanning these pages.