For more than a decade, the CIA has deployed drones, satellites, spies, informants and tracking devices to thwart al-Qaeda. The spy agency also considered a plan to wage war with toys, The Washington Post reported.
Beginning in about 2005, the CIA began secretly developing a custom-made bin Laden action figure, according to people familiar with the project.
The face of the figure was painted with a heat-dissolving material, designed to peel off and show a red-faced bin Laden who looked like a demon, with piercing green eyes and black facial markings.
The code-name for the bin Laden figures was "Devil Eyes", the report said.
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To create the doll, the CIA turned to one of the best minds in the toy business, the report said quoting those familiar with the project.
The toymaker was Donald Levine, the former Hasbro executive who was instrumental in the creation of the wildly popular G.I. Joe toys that generated more than USD 5 billion in sales after hitting the shelves in 1964.
There's a dispute over how many of the figurines, if any, were ultimately delivered, the report said.
A person with direct knowledge of the project in China said hundreds of the toys were made as part of a pre-production run and sent on a freighter to the Pakistani city of Karachi in 2006.
"To our knowledge, there were only three individual action figures ever created, and these were merely to show what a final product might look like," CIA spokesman Ryan Trapani was quoted as saying.
Bin Laden was killed in the garrison town of Abbottabad on May 2, 2011, in a covert raid carried out by the Navy SEALs on a special order issued by President Obama.