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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 … Read More
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. Released in summer 2013, the final ‘astro boys’ are made in the USA using 100% recycled plastic milk jugs. Design sketches by Brian Gulassa Read Less
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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.