3D Harry Potter Book Game

Book-shaped Happy Meal toy with two Harry Potter board games

For my EGR 121 course, my team was challenged to design a Happy Meal toy that was fun, low-cost, safe for children, sustainable, and suitable for high-volume injection moulding. We deliberately started with broad brainstorming before introducing constraints, exploring ideas including mechanical maze toys, collectible objects, DIY kits, and game-based concepts. We then screened each idea against criteria including choking safety, manufacturability, cost, originality, educational value, and appeal to children. The final concept was a foldable Harry Potter-themed book game. When opened, the book contains two board games, four playing pieces, and a page flap that creates the experience of turning a real book page. A die was designed to be cut from the Happy Meal packaging itself, reducing the need for an additional manufactured component. The product was also designed as a collectible system with five versions: one for each Hogwarts house and a rare all-houses edition. The engineering challenge was making the toy both playful and manufacturable. We designed snap-fit and sliding mechanisms instead of using screws or adhesives, carefully toleranced the cover, clips, and page flap, and enlarged the bases of the game pieces to meet choking-hazard requirements. The parts were designed with relatively constant wall thickness and filleted edges to improve injection mouldability. The final six-part design had an estimated manufacturing cost of **$0.49 per toy**, staying within the project’s cost constraint while remaining safe, collectible, and mass-producible. **Skills developed:** CAD, DFM, injection-moulding design, tolerancing, cost analysis, product ideation, safety constraints, manufacturing planning, and collaborative engineering.