Happy Meal Ball Maze Toy
Technologies:
SolidWorks
Injection Molding
Rapid Prototyping
Design for Manufacturability
Project Overview
- Designed a puzzle maze toy with interchangeable backgrounds for Happy Meals.
- Used SolidWorks for CAD modeling and tolerance analysis for manufacturability.
- Developed a cost‑effective design with ABS plastic to ensure durability and safety.
- Implemented injection molding manufacturing with an estimated cost of $0.38 per toy.
- Conducted user testing and improved friction‑fit tolerances for an optimal user experience.
Technical Drawings & Prototyping
Project Documentation
Cost Analysis
- Manufacturing Cost: The total cost per unit was estimated at $0.38 using injection molding.
- Material Costs: ABS plastic was selected for its durability, low cost, and recyclability.
- Production Feasibility: The mold was designed for high‑volume manufacturing, reducing per‑unit costs as production scales.
Marketing Analysis
- Target Audience: Children ages 3‑10, incorporating popular themes (Encanto, Cars, Lightyear).
- Brand Alignment: The design integrates with McDonald’s existing Happy Meal branding, enhancing collectibility.
- Sustainability Considerations: The toy is designed for recyclability and minimal material waste, aligning with sustainability goals.
Project Results & Key Findings
- User Testing: Positive feedback was received on ease of use and durability.
- Manufacturability Success: The toy was successfully manufactured using injection molding, demonstrating feasibility.
- Improvements: Adjustments to snap‑fit tolerances and friction joints improved the final design’s assembly quality.