Aiden Dibuono

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Aiden Dibuono

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INJECTION-MOLDED VEHICLE DESIGN

TURNING GAME INSPIRATION INTO ENGINEERING

Collaborated on the full design, CAD modeling, and manufacturability planning of an injection-molded vehicle inspired by Clash Royale, learning to balance creativity, functionality, and manufacturing constraints.

Project overview

Working as part of a four-person design team, we developed an injection-molded vehicle modeled after Sparky from Clash Royale, a concept chosen for its challenge and visual complexity. The goal was to translate a digital design into a realistic, manufacturable product while accounting for the limits of injection molding.
Through concept sketching, CAD modeling, and iterative refinement, we adapted a playful game element into an engineering design that could be built using practical materials and mold geometry.

highlights

Concept to CAD

Turned hand sketches into 3D models using Solidworks. Then we used these sketches to create mold geometry for injection molding.


Design for Manufacturability

Modified complex shapes to remove undercuts, maintain uniform wall thickness, and ensure mold-friendly geometry.


Feature Prioritization

Preserved defining elements like Sparky’s blaster and front plow while simplifying the body and wheel structure in anticipation of real-world problems.


Injection Molding Planning

Split the design into two main molds plus a separate front plow to optimize tooling in the real world and in Mastercam.


Material and Production Insight

Gained hands-on understanding of how plastic flow, draft angles, and parting lines impact the final product, and developed experience in Autodesk Moldflow.


Modeling for Troubleshooting and Visualization

Utilized 3D printing to visualize Sparky and anticipate design challenges before creating the final Solidworks model.


Team Collaboration

Worked closely to balance creative ambition with mechanical practicality—turning a “game vehicle” into a legitimate engineering model.

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