Through brainstorming we developed as toy design that met all the requirements and constraints. Our design is a totally enclosed system, such that it has no free components that would pose choking hazards. It's outer surfaces have no creases or crevices that bacteria could be caught in and is easily sterilized. The toy functions as a maze where the balls travel throughout the obstacles which correspond to components of the water cycle. The user guides the ball through tilting the game and spinning the discs to maneuver the ball through each part of the water cycle to learn about it interactively. On the back of the toy their is art designed by a University of Colorado art student that describes the stages of the cycle corresponding to the toy, it also has a legend that describes what each disc represents. 

​Initial Pretotype: A pretotype is essentially a rough draft of your final design used to demonstrate how it will work. Our pretotype was made from scrap material we found for almost no cost, such as acrylic, scrap nails at the plinko style obstacles, thumbtacks as knobs, and plywood. 

Pros:

• Demonstrates plausibility of the design
• Shows necessary changes that need to be made to size
• Cheap to fabricate
• Quick and easy fabrication

Cons:

• Not final product quality
• Too large/heavy (3.2 lbs)
• Not aesthetic

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Iteration #1: We built a more user friendly toy based on the positive feedback we received from our pretotype. This toy was designed to be used for hands on testing with children to receive end user feedback.  The cover was made easy to remove via Velcro to test variations in disk design.

Pros:

• Game play is fully functional
• Received good feedback from users
• Looks closer to final product quality

Cons:

• Corners are relatively sharp 
• Too heavy (3.4 lbs)
• Too large dimensions make difficult for children to handle (13" x 8.5")
• Balls occasionally skipped disc during use 
• Acrylic  fractures easily

Changes:

• 3D printed disks made of ABS plastic
• Steel dowel pins acting as plinko obstacles
• Painted discs for improved aesthetics

Iteration #2: Through the user feedback we received we made some significant changes to the overall design. We continued using Velcro to bond the cover to further test disc designs. 

Pros:

• More durable design (Polycarbonate exterior less prone to fracture)
• No issues with balls passing discs without rotation (due to smaller width)
• More aesthetic obstacles (clouds and skyline)
• Smaller dimensions and weight

Cons:

• Lack of color
• Corners sanded but still too sharp
• Metal dowels are unappealing aesthetically
• Metal balls were unappealing (via user feedback)

Changes:

• ​Smaller dimensions (12.5"x7.72")
• Lighter weight (2.7 lbs)
• More detailed skyline and clouds
• Less plinko obstacles
• Polycarbonate exterior

Iteration #3: This is our final prototype, we incorporated the changes discovered from the previous iteration. 

Pros:

• Further improved aesthetics
• Multiple balls (10 total) improve appeal to children
• Smaller dimensions (12.38"x7.21")
• Decreased weight (2.4lbs)

Cons:

• Small leaks of solvent (Dichloromethane) caused smudges
• Art is slightly misaligned with obstacles

Changes:

• Removal of plinko style obstacles
• Further detailed the skyline
• Use of stickers on front and back to describe water cycle and make more aesthetic
• Added rainbow and sun to add color
• Use 10 balls of varying colors
• Rounded all exterior edges via CNC mill

Iteration #1 with Kodo: Our initial design with Kodo was to test the idea of making the entire body of polycarbonate. 

Pros:

• Increased durability by using polycarbonate unibody
• Rounded corners

Cons:

• Polycarbonate clouds when machined causing art background difficult to see
• Metal balls unappealing
• Disc designs are too realistic, making unappealing clash with simpler cloud and skyline
• Cover was fastened tight enough

Changes:

• Rounded corners
• Body and cover made of polycarbonate
• Machined raindrops to replace plinko obstacles
• All obstacles and unibody components machined out of one piece
• Screw fastened cover

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Iteration #2 with Kodo: Based on the issues with our initial Kodo design we made further changes. This is our final product, it incorporates the feedback received from the engineers at Kodo, such as designing for manufacturability and improving aesthetics. 

Pros:

• More secure fastening system used on cover
• More aesthetic design (simplified disk design matches other components)
• Rounded knobs improve manufacturability
• Very secure cover
• Easily sterilized and durable

Cons:

• Initial balls (2.5 mm diameter) got stuck in disc slots (now have been replaced with larger balls)

Changes:

• HDPE white unibody
• Simplified disc designs
• More screw fasteners incorporated
• Silicon molded disk designs (smooth sil 940)

Step 1: Define the Problem

Step 2: Collect information

Step 3: Brainstorm & Analyze Ideas

Step 4: Develop Solutions / Build a Model

Step 5: Feedback

Step 6: Improve the Design