I work with brands such as Disney and Universal Studios to deliver licensed products.
Licensed Character Squishy Lights
Requested by: Buyers and Product Managers
Briefs: Create a [character] squishy light that is manufacturable and meets the licensor's requirements for the character design
Mickey and Minnie Squishy Lights
Research
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For the Mickey and Minnie Mouse squishies, I looked up existing products for reference
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Usually when I do research, it is to find opportunities to differentiate my products from competitors; however, in licensing cases I usually can't stray too far from what's been done since it's strictly regulated
Process - Mickey
Programs used: SolidWorks, Blender, Keyshot, Photoshop, Illustrator
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1
First drafts
2
Challenges
Disney wanted:
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Detailed classic style with the top torso being shown
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Just the heads of characters aren't allowed in a design
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This image is in the exact pose Disney wanted
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My concerns:​
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How would this be modeled and manufactured?
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It was unrealistic to model a character like this in SolidWorks
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Small amount of time
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Must be extremely accurate to meet Disney's standards
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Disney's 3D models could only be used as a reference
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An animation modeling software like Maya would be easier to use
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Wireframing could be used to position the model relatively quickly
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Maya is expensive, but Blender is FREE
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After watching a few video tutorials, I was able to use Blender as a shortcut for my modeling process
3
First approved concepts
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My colleagues wanted to pursue this version
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It proved impractical to manufacture as I suspected
...It was also evident that some manufacturers did not want to say no to the task but also didn't want to do it
4
Final concept
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Complicated forms failed
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We pursed a minimalistic, stylized form instead
5
3D prints and rough mockup testing
6
Final product
Process - Minnie
1
The bow
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Minnie has almost the exact same character design as Mickey, so the only additional part to design was the bow
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The initial concern was how the bow would blend into the ears if it was to come out of one mold
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We ended up using a two-part mold so the bow could be separate from the ears
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2
Polka dots
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The factory was unable to print the original polka dot layout on the deeper creases in the bow
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After some discussions with Disney, I reduced the size of the dots and fit more on each side
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I declined to put anything on the center "knot" of the bow
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We'd only be able to have one in the very center which would have looked awkward
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3
Final concept
4
3D printing and rough mockup testing
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The last change with the polka dots was too close to the product release date
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We continued to use the version with fewer polka dots
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We had a running change made to all the future Minnie Mouse squishies moving forward
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Programs used: SolidWorks, Keyshot, Photoshop, Illustrator
5
Final product
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This is the version with fewer polka dots
Process
Products used: SolidWorks, Keyshot, Photoshop, Illustrator
1
Sketches
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......
2
Initial challenges
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Initially, Universal wanted to change the facial features and add blush spots that had a gradient on the edges
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The factory unable to do that effect
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The factory also asked me to remove some elements because they exceeded the number that could be printed
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I ended up removing the blush, changing the mouth, and widening the base so we could reuse an existing light engine
3
Approved concept
4
Mockups
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The mockup for Cakey Cat turned out well
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Our modelmaker made it using:
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3D printing the model from my .stp file
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Bondo and sanding
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Spray paint
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Decals printed onto transfer adhesive
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A comparison of the model that we made (left) and the model the factory made (right).
5
Additional challenges
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The factory asked for more changes before production
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They needed the number of colors to be reduced to 6
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There was trouble getting the colors in the base
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They tried doing three solid stripes instead of gradients, but could not get a consistent, even look with injection molding
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I took away the ridges in the base so that it could be smooth for a heat applied label
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I also made a label that mimicked three dimensional ridges in Illustrator
4
Alternative concept
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Universal did not approve this ​
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We decided to make the "head" and the "wrapper" two parts
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The "wrapper" is ABS plastic so it can be spray painted
Sold under
Found at these major retailers
Star Squishy Light
Research
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There weren't any existing products since this was a new movie, so I relied on Disney's creative assets for licensees, which I'm unable to share
Process
Programs used: SolidWorks, Keyshot, Photoshot, Illustrator
1
Sketches
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This was probably the easiest character I've ever worked with
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Its simple form made it easy to model and manufacture
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2
Initial concepts
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The squishy light was originally going to be white with a heat transferred label for the face and RGB lighting
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There were also small changes to the form and positioning of the "limbs"
2
3D models
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Looking at different sizes of early concepts
3
Approved concept
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Disney wanted the entire body to have the character's golden color
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We decided that the light should only be warm white to avoid the colors looking muddled
4
Final mockup
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This was sent to Disney as the final stage of approval
5
Final product
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The heart shape of the face was too large for the label to look good
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We used a two-part mold instead while still using labels for the eyes and mouth
Sold under
Found at these major retailers
