2.008 Yo-yo

As part of MIT's Course 2 Curriculum in the Design & Manufacturing II Lab, I worked with a group of fellow engineerings to design and mass manufacture over 100 yo-yo's of our choice. We collectively brainstormed an original design for our yo=yo, modeled the product in Fusion 360 for pressfit assembly, programmed CNC machines to make molds for our design, optimized system parameters for manufacturing (injection molding, inkjet printing, thermoforming processes), and evaluated the performance of our processes across 50 yo-yo's. I was able to learn so much more about designing for manufacturing and system optimization. I primarly had ownership over the design, CAD, and thermoforming the parts of our yo-yo.

Original Design Plan

Critical Dimensions

Base thickness is constant at 0.080 in except for the lower base at 0.165 in
Clicker thickness ranges from 0.080 in to 0.135 in through the part, due to design geometry requirements
Retaining ring thickness is 0.082 in throughout the part

Tolerances

Gap between the retaining ring and the base: 0.041 in
Thermoform part thickness ~ 0.033 in
Press fit gap between the base and the retaining ~ 0.005 in
Gap between the light and base is 0.023 in
More of a gap between the top of the base and the bottom of the retaining ring than the base to dome to ring

Scaling and draft angles

Scaling: All parts were scaled up by 3% to combat the max shrinkage of polypropylene. This might have to be adjusted after our first set of molds gets made
Draft Angles: Draft angles were added to both the base’s interior walls. This angle is very small ~1˚, but also might have to be adjusted

Manufacturing revisions

Production, Assembly, & testing

Evaluation

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