We brought the working prototype to a DFM shop to seek support to make the product manufacturable. We worked with hardware shops on PCB board design, schematics, Gerber design, and tooling.

For the fabric and redesign of the look of the plush, including different ways to fix the sensors inside the plush toy, we consulted various plush factories.

We proposed a very unique challenge:

• Our sensors are not just buttons, but soft sensors that need to be fixed in the plush seamlessly, while still keeping the cuddliness of the toy.
• All the sensors need to be soft and not provoking, including LED, RFID and other sensors that normally are fixed inside a plastic box.
• We asked to put 11 wires/ sensors inside the plush. This was a unique factor as, normally, the “singing plush toys” have less than 4 wires.