Plastic toy shovel

The assignment was to design and technically develop a plastic toy shovel, with a focus on manufacturability, material choice and mechanical loads.

The challenge lay in developing a product that:

• Is suitable for mass production via injection moulding
• Is sufficiently strong and durable for use by children
• Can withstand various loads (bending, impact, wear)
• Meets safety standards for toys

In addition, the design had to be fully substantiated with analyses in the areas of material, mechanics and production.

The final result is a fully developed design of a plastic toy shovel, including a 3D model and technical substantiation. The design includes, among other things:

• A thin-walled, injection-mouldable construction with draft angles and fillets
• An ergonomic handle and smooth transitions between components
• A form that can withstand various usage scenarios
• A material choice (ABS) with a good balance between strength, toughness and cost

• Analysis of loads and critical usage scenarios
• An extensive requirements specification
• Material research and selection via EduPack
• CAD development in SolidWorks including draft analysis

I carried out this project independently, going through the complete technical design process. My approach consisted of:

• Analysing existing plastic products and production methods
• Researching loads and usage scenarios with children
• Drawing up a requirements specification
• Conducting material research and selection using EduPack
• Designing and modelling the shovel in SolidWorks
• Optimising the design for injection moulding (draft, fillets, shell)
• Verifying manufacturability with draft analysis

• Technical development of the design
• Material choice and substantiation
• CAD modelling and validation
• Translating requirements into a manufacturable product

The result is a strong response to the assignment because:

• The design is fully injection-mouldable and suitable for mass production
• Realistic loads and use by children have been taken into account
• The material choice is substantiated with technical and economic criteria
• The design meets safety and usability requirements
• Ability to conduct and apply technical analyses in design
• Ability to develop a product with a focus on manufacturability
• Material science can be translated into practical choices
• Strong ability to work with CAD and design validation
• Ability to independently develop a technical design from analysis to final model