Mass-manufactured latte yo-yo
Roles: Mold Design (3D Printed and Machined), Manufacturing (Injection-molded base)
Skills: Design for Manufacturing, CAD (SolidWorks), CAM (MasterCAM), 3D Printing, CNC Milling, Injection Molding, Quality
Time: September - December 2018
Developed as part of 2.008, Design & Manufacturing II
The goal of this project was to design a yo-yo for manufacturing at scale.
Due to a shared love of coffee shops, my team designed a yo-yo based on a latte. The yo-yo required a base with a fitted metal shim for weighting, a snap-fit between the “coffee” and the base, a fit between an injection molded “coffee” and the thermoformed part “foam”, and a thermoformed “cup.”
The yo-yo was first modeled using SolidWorks.
This model was then used to design the molds. MasterCAM was used to create the toolpaths for creating the molds from aluminum and then the molds were made using a CNC mill and a CNC lathe. A mold was 3D printed using an SLA printer for thermoforming the “foam.”
Test runs were conducted for all of the parts to optimize the process parameters and ensure the parts fit together as desired. The molds had to be modified a couple of times to improve the snap-fit. Finally, we did a production run and produced 100 of each part (50 of the cup) and assembled 50 yo-yos.
The full process is shown in the video below.
The final yo-yo is shown with and without its “cup” below. The yo-yos were subject to a drop test to ensure that they did not fall apart.