Case History – Motorbike Toy

DESIGN BRIEFING
The product to be developed is a TOY MOTORBIKE for children aged 3 years.
It is linked to real motorcycles in terms of sportiness or comfort, and indications are provided regarding the article’s industrial cost, number of components, materials, and total weight.
The company’s business idea is accompanied by comparison with competing products as well as an attractive and personalized design.

 




AESTHETIC MODEL SCAN
The aesthetic model is scanned using photometric equipment that can detect the surface shape of an object of any size and hardness, because detection is contactless.
Since there was no digital data or dimensional design, the scanning technique served to detect the shape of the plaster model as well as its dimensions, including the wheelbase and regulatory values.




MATHEMATICAL RECONSTRUCTION OF EXTERNAL SKINS FROM SCAN
REVERSE ENGINEERING is conducted using cutting-edge technology. In this phase, 3D surface reconstruction is carried out which is faithful to the aesthetic lines of the scanned physical reference model.
The reverse engineering process is completed with verification of the dimensions imposed ​​and subsequent surface quality check.




COMPONENT DESIGN
This is the broadest developmental phase because it concerns the proportioning of all the bike’s components and includes:

  • Application and analysis of SAFETY STANDARDS and the mechanical constraints imposed by final testing agencies
  • Adaptation of existing components complementary to all or part of the client’s article, e.g. wheels, electrical system (batteries and cables), handlebars.
  • Design and 3D MODELLING of the components of the external “skin”, previously constructed from the scanned plaster model and sketches. In this phase, construction balances the article’s aesthetic needs and the technical/structural requirements of plastic.




VERIFICATION OF SURFACE QUALITY
This activity includes analysis of all constructed surfaces to verify their aesthetic and technical quality, including verification of:

  • TANGENCY alignment or CURVATURE of the surfaces in the required penalty class via reflection of appropriately projected textures and lights. Quality parameters are obtained from the graphic results.
  • Verification of the TECHNICAL DRAFT highlighted in the 3D model, with colour change represented via a graphic scale corresponding to variation in the draft shades.




 

ASSEMBLAGGIO DELL’ARTICOLO
In questa fase vengono posizionati e ASSEMBLATI tutti i componenti modellati nuovi con i componenti esistenti da integrare con l’obiettivo di verificare: Interferenze, giochi, errori dimensionali, ma anche per valutare il risultato estetico generale.

Vengono quindi considerate le modifiche suggerite dal gruppo di lavoro e apportate al modello matematico prima della successiva verifica prototipale.

 




PROTOTYPE PHASE
In the prototype phase the design is subject to a real, PHYSICAL CHECK.
The prototypes for the newly designed components are built using the technique of stratifying molten nylon powder.
The bike’s aesthetics, functionality and assembly will be verified.
This is the most important verification phase because the working group plans any changes and adjustments necessary for the product’s functional optimization and the improvement of the industrial parameters and mould construction specifications.

 



PRODUCTION OF TECHNICAL DATA SHEETS
When all modifications and/or optimizations agreed with the client, mould-maker, and production manager have been made to the design, the article’s development can be considered complete.
TECHNICAL DATA SHEETS are produced for use by for all production departments:

  • mould construction sheets (mould layouts, surface finishes, extraction points, etc.)
  • production sheets (colours, article pre-assembly)
  • Assembly instructions for the end customer

TRIAL

After the FIRST MOULD TESTS, the product is assembled and checked for moulding anomalies, ease of assembly and design consistency.

 



FINAL PRODUCT
The final product, complete with graphic look, is ready for sale. It can be used by children aged three years upwards. The article’s functionality and aesthetics will be judged by the market.

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