Manufacturing and Designing a Toy Bugatti
Start-to-end design, manufacturing and assembly of a 1920s Bugatti Type 35
Fig. Detailed CAD via Fusion360
The Problem
Fabricate a durable, functional toy car within strict material, tooling, and process constraints
Translate detailed CAD geometry into manufacturable molds and tooling
Execute multiple manufacturing processes + maintain dimensional accuracy for fit
Fig. CAD model of the vehicle body
The Approach
Modeled the car body and components in Fusion 360
Used the cavity feature to create a 3D printable mold.
Casted the vehicle body with Silicone
Fig. Final silicone casted vehicle body
Fig. CAM milling of wheel mold
Fig. 3D printed mold for casting
Fabricated molds using CAM milling for steel tooling.
Used the steel mold to inject plastic and create wheels
Fig. Final steel mold used for injection molding
Produced and evaluated multiple prototypes to identify casting defects, mold leakage, air entrapment, and structural issues. Refined geometry, tooling, and assembly features based on observed failures.
The Result
Successfully created molds and casted with various materials
Learned CAM techniques to create steel molds for DIY injection molding
Final model selected as Mechanical Engineering Department exemplar