For my 2nd year engineering design course, we created a “toy” called Boss Tank. My group comprised of Julian Di Leonardo, Jake Nusca, Jacob Gillson and myself. The objective of this project was to design a toy that will fit disassembled into a 10 cm tall by 8cm wide plastic egg. This egg will be sold to children who will assemble and play with the toy. From the technical constraints given by the company; the toy must have parts which require assembly by the child and must not contain any stored potential energy in its disassembled state. The toy must also be at least 50% printed ABS plastic by weight. Once assembled, the toy must be able to store some form of potential energy and remain in place unaided until the child starts its run. An example of the wheel locking mechanism used to accomplish this, modelled in Siemens NX7 (an advanced CAD/CAM/CAE software package) can be seen below:
The toy can be set into motion by the child at any given time. When the run has begun, the toy must then travel at least 2.5 metres. The speed of the toy while it is running should be as high as possible while still being safe and under control. When is has finished moving, it must still be in a state where a second run is possible with minimal or no effort required for reset. The toy will then be marketed to the board of directors for approval.
If approval is given, the toy will go into mass production. All parts of the toy must be easy to manufacture and the total production cost must be low enough as to provide ample profit margins for the company. The method of production must be high yield and the parts must not pose any danger to the children during assembly or play. With all of these constraints in mind, a toy was developed that will be safe, easy to assemble, and very fun to play with.
Using team brainstorming and decision making methods, an initial prototype was developed. Through engineering design and development, concept mechanisms for propulsion and locking were created and tested until a suitable working model was created. After all of the designs had been reviewed by the team, a prototype was printed and tested to assess the effectiveness of the mechanisms. This prototype, through testing and analysis, was continually improved until a final design was achieved.
The final design was then assessed based on manufacturing cost and practicality. Using average industry standards, a cost model for the materials was created to assess the practicality of mass production. From this cost model, it was found that one injection moulded ABS Boss Tank unit would cost $0.891 USD. Once the design was assessed for feasibility, a marketing model was constructed that would set an appropriate theme and appeal to children ages 5 and up. A line of TV and magazine ads will be launched to raise awareness of the product, an example of which can be seen below:
Boss Tank Youtube Commercial