Chuckbuddy was created by a professional snowboarder to while away the hours away from the slopes. The flexible action figure was designed and manufactured, and had been well received at trade shows throughout Europe. Manufacturing issues meant they needed a design company to reverse engineer the existing product and create high quality manufacturing data to re-tool the product. We were also tasked with developing new mechanisms, snowboard, skis, and ski poles.

This project required the reverse engineering of multiple interlocking components with complex geometry, all modelled to suit the injection moulding process. We used a combination of dimensional measurement, 3D scanning technology, and advanced surface modelling to map and reproduce the complicated surfaces of the existing product. The whole product was modelled in SolidWorks and exported in file formats suitable for the chosen manufacturing processes.