LINK partnered with the team at Sprig to design, engineer, and domestically manufacture this novel line of toys. Highlights of the product include injection molding with a unique, recycled material (HDPE + reclaimed woodchips), battery-free operation, and design for quick, easy assembly. These products hit the shelves in the fall of 2008 and were an instant success, spawning an entire new line of products! The brand was sold to Wham-O Toys and was just recently bought back by the original owners.
These toys were meant to take abuse. LINK performed FEA on the chassis components and push handles, and used analysis to help design the snaps used during assembly.
The entire line of toys were modeled in Solidworks and completed with manufacturing specifications and drawings. Working close to the injection molder and manufacturing assembly operation allowed Sprig to get to full production fast.
Our goal was to use zero screws in the part to keep assembly costs low, and we ended up pretty close to that in the end. And having just a few metal parts for the battery-free power source meant the toy can be easily disassembled and recycled properly at the end of its life. Besides being earth-friendly and looking really cool, kids have a blast playing with them as they create adventures and follow the story lines of the characters.