There are four parts in the assembly, the base, the triangles, the blue lining inside the triangles (or spider as we call it) and the thermoformed design. For the base, triangles and spider we will be injection molding the parts while for the thermoformed design, which is different on both sides, we will be thermoforming each of the designs. Then when we put the yo-yo together we will place the thermoformed design in at the bottom of the base and then then snap fit the triangles and the spider over top, with each snap fitting into the base but not each other.
When Designing the Yo-Yo
1. We made sure there were no undercuts where a mold would get caught on the piece.
2. We made sure every face was drafted correctly so it would be easier to remove from the mold.
3. We scaled about 1.5% for shrinkage as estimated from parts/molds of similar size.
4. We made sure snap fit dimensions were sized properly.
5. We took out all sharp corners where possible and filleted instead.
6. We thinned the part in certain places to make sure it would cool properly.
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