The Canadian singer opted for a new haircut earlier this year just before he turned 17 - a sudden move that left The Bridge Direct company reeling, according to CNN.
Gone was his trademark shaggy sideswept 'do' and in place was a funky, shorter look.
'First off, I had no idea what he did,' said Jay Foreman, founder and CEO of the Florida-based firm, which hit the jackpot in June 2010 by scoring an exclusive license to make Justin Bieber dolls.
'I heard a lot of shrieks around me, and people running in and out of their offices.'
The unexpected chop meant the firm, based in Boca Raton, had to alter its autumn 2011 round of manufacturing to reflect Bieber's fresh image - a last minute switch now revealed to have cost $100,000.
'We didn't want to disappoint fans with a Justin Bieber doll that doesn't look exactly like him anymore,' added Foreman. 'But there wasn't much we could do about it.'
So although the new Bieber figurine set to hit store shelves soon will retain his former sidesweep style, Bieber's hair has since been changed for the second round of production.
'Would I rather that Justin called me three months before he made a hair change? Yes. But we know that won't happen,' said Foreman.