SUNSTAR CRAYOLA TOOTHBRUSH
The Overwatch team was asked by Sunstar to improve the design and assembly of the Crayola powered toothbrush. The complexity of the electromechanical design aligned well with Overwatch’s experience. This was truly a collaborative effort between industrial design, mechanical engineering, and manufacturing launch support.
The previous version of the product had over 40 steps in the assembly process. In addition, the old design did not allow for the product to be tested until the device was fully assembly. There was no ability to inspect or rework units at the end of the manufacturing process.
Reduced product cost and improved quality were accomplished by designing a clever inner carrier assembly. This carrier allows the internal subassembly to be built and tested before final assembly into the outer cosmetic body. The carrier enables more precise location of the motor and gearing. In addition, the new carrier design eliminated several screws and removed two ultrasonic welding operations.
This new design became a platform for several other battery powered toothbrushes including Star Wars™, Dino Train™, and Power Rangers™.