This study was conducted for a Chinese toy manufacturer to explore alternative product architectures for action-based toys under strict cost and manufacturability constraints.
The objective was to evaluate whether a simplified construction—combining readily available materials with a limited number of 3D-printed components—could deliver comparable or improved user engagement compared to existing market products.
The prototype consisted of a blow-activated toy built around a standard aluminum conduit, paired with custom components including a mouthpiece, handle, and sight element. The system was designed to remain compatible with widely used foam projectiles and incorporated integrated storage to reduce part count and assembly complexity.
User testing with early childhood and school-aged participants focused on:
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ease of use and physical engagement
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perceived control and tactility
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preference compared to more complex, feature-heavy products
The study revealed a consistent preference for the simplified, tactile interaction, suggesting that reduced complexity can increase engagement while supporting lower production and tooling costs.
This project is presented as applied research into how material choice, interaction design, and structural simplicity can inform cost-efficient toy development for large-scale manufacturing.
(Presented as exploratory research conducted for an industrial client.)
