• astro boy
    fathom // spring 2012
  • Green Toys needed an astronaut to accompany their rocket toy set, and they asked Fathom to take on the 3D CAD design. I brought the concept from rough clay model and sketches into production-ready form. We then tested the final design by 3D-printing a rapid tool and shooting some parts out with our in-house injection-molding press. 
     
    The final toys are made in the USA using 100% recycled plastic milk jugs.
  • These are the initial concept sketches, based on a rough clay model. Various features changed through the design process, such as going to a double jet pack for more efficient material yield and mold flow. 
  • final 3D CAD, modeled in Rhino. Astro boy is hollow and open at the bottom to accomodate a sliding mold-core. This allows for a faster cycle time and much less material consumption.
  • We tested the final design by 3D-printing a rapid tool and shooting some parts out with our in-house injection-molding press. (sliding core not shown in the above rapid-tool photo)
  • Released in summer 2013, the final ‘astro boys’ are made in the USA using 100% recycled plastic milk jugs.