Stamped Dragon Assembly

The other manufacturing method we looked into was plastic stamping. This part of the design effort was led by one of my teammates.

Each part separately costs less with plastic stamping, but the starting cost associated with the dies for plastic stamping totals more than the dies for the injection molded dragon.

This prototype was laser cut out of polycarbonate, instead of stamped out of vinyl (chosen for its high flexural strength) like the actual product would be.

This dragon is about ~2.25 inches in length; so while it does fit in the Kinder Joy egg, its pieces could be considered a choking hazard.