2.008 Yo-Yo - Jellyfish

My team's yoyo for MIT's 2.008 class on Design and Manufacturing. The goal is to design a yoyo that is mass-manufacturable using injection molding and thermoforming and produce a minimum of 50 yoyos. Our team decided to add electronics to the yoyo for a bit of sparkle.

Lighting Design

Fusion 360 Render

Led team of 5 to design a visually appealing yo-yo by giving feedback through photorealistic rendering of concepts

SLA Prototyping

Made a custom SLA resin to match optical properties of injection molded plastic to understand light dissipation within the yoyo

PCBA Design and Manufacturing

Goal: design a circuit that fades lights in a small form factor for under $2/unit

Utilized digital logic ICs and low-pass filters to achieve fading pattern while keeping costs low
Sent out Rev A to fab within 12 hours of the first lab meeting as a proof of concept
Sent out and received Rev B boards at a total cost of $1.15/PCBA
Soldered 225 PCAs in a reliable and process-controlled manner
Created custom jigs to aid in consistent part placement

Injection Molded Part Design - PCA Holder / Light Diffuser

Mold Design

Utilized Non-planar parting lines to increase flexibility of mold
Optimized part for low cooling times and low injection pressures

Part Perfection

Mixed a blend of translucent PP pellets and sourced clarifying agents to achieve a uniform diffuse
Tuned molds to ensure proper sealing of nonplanar faces to prevent flash

Integration

Compliant arms allow for large tolerance variation between the main body and PCA retainer
Heat staked PCA ensures fast assembly times