We decided that from the feedback we got during the design review, we compromised on too many aspects of our previous design and lost our "wow factor." We stuck with the frozen yogurt theme instead of possibly switching to ice cream to make it easier to design.
We decided that our injection molded parts would include:
- Waffle cone cup
- Chocolate syrup
- Cherry
3D Printed Part:
- Cherry Stem (We decided to not go with the Wikki Stix and 3D print them instead. We were worried about the lifetime of the Wikki Stix and didn't want them getting gross shortly after manufacturing the yoyos. We also decided to 3D print it instead of injection molding because we are limited by the smallest tool size, which is too big for the size of the stem we wanted.)
Thermoformed Part:
We decided to have the froyo piece still snap fit into the waffle cone, but we put the snap fit much higher up than in our previous design. We were concerned that our fingers wouldn't fit in the cup in the previous design and it would be hard to snap fit into the cup. With the snap fit up much higher, this should not be a problem. This new design also eliminates the need for a snap ring, with the froyo and cup piece snapping together by themselves.
We decided to still eliminate the m&m's and do a chocolate syrup injection molded piece instead. This way we are not gluing anything onto the froyo. We are injection molding the syrup rather than thermoforming so that it has a nice surface texture. The syrup will sit on top of the thermoformed froyo piece and will have a square insert that fits into the froyo so that it doesn't rotate.
The froyo piece will snap fit into the cherry, which will also hold the chocolate syrup in place. We will then 3D print the cherry stem, which will be inserted in to the cherry and then be held in place when the cherry snap fits on.
The waffle cone cup texture does have really small undercuts; however, the part will shrink onto the core, which has no undercuts, so it will shrink away from the waffle cone texture.
We created a mold for the most complex part, which is the waffle cone.