Tao Tao’s Plush Night Light Proposal

Initial ideation

My best friend Cecily has a two-year-old named Zoe, and when I design for kids, I’m designing for Zoe. Ultimately, with my night light concepts, I was primarily thinking about Zoe.

While I tried to mine the depths of my cranium for any unique ideas, I kept coming back to the usual suspects: sources of light, and perhaps the emanation of music. I pushed myself to brainstorm within more conceptual realms, but just kept hitting blank walls. While I think a vintage-style camping lantern or flashlight could’ve been a neat decorative pillow or vintage-y collectible, all roads eventually led to the anglerfish. I mean, what creature on this earth has a cooler source of light?  

Focusing in on the anglerfish

Story & Target User

Thanks in part to Finding Nemo, the anglerfish is now a notorious deep-sea beast. And you know who loves beastly beasties? That’s right—kiddos.

This plush anglerfish is a bona fide predator—if your other stuffies aren’t careful, Zeeborgle might lure them in and gobble them up! In simpler terms, Zeeborgle is the ultimate ugly doll.

Anglerfish plushie pattern

The target user is a child aged 3-6, who is still excited about stuffed animals and creating stories (and rivalries and scandals and dramas, oh my!), that may or may not involve one stuffie gobbling up another. They hopefully will not tug the light-up lure, as that would break the circuit and potentially put them at risk. More there to consider, I’m sure.

Anglerfish plushie prototype

Planned Materials & Components
For the main body of the fish, including the dangly light lure, I plan to use a soft, fuzzy plush-style fabric. In addition to the fluff-stuffing, I’d like to put wire within the lure, so that it can be bent in different directions. The same fabric will be used for the teeth, which will be sewn and then attached separately. The fins will be a thinner, possibly shiny or metallic cloth, sewn onto the main body (note: I found it very tough to create wavy shapes at such small sizes). For the eye, I’d like to sew a mini plush oval, potentially with a small Velcro or magnetic component so that the eyeball can be moved to look in different directions.

Another neat feature would be Velcro on the teeth plus a pair of little fish that can then be “lured” into the mouth and caught in the teeth. I’m thinking this could be a fun interactive element, to extend the toy’s lifespan, before it gets relegated to the back of the closet.

Thoughts & Next Steps
Lots of anglerfish plushies exist on the internet (some of which light up, like this one, which is also a puppet). I was initially discouraged by this, but it was ultimately still the idea I was most excited about. To differentiate it from existing toys, I thought about the adjustable wire lure and the Velcro within the teeth. Even better would be if the little fish got gobbled up all the way into the stomach—maybe something to explore in my next iteration. Also, I feel like my current prototype leans in the “ugly doll” direction, which is different from the other versions I’ve seen in circulation.

Very excited for the next stage and keen for any suggestions!

Electric Toothbrush Teardown

Behold as the electric toothbrush self-assembles!

Welcome to the Taodown! Otherwise known as the Tao Tao Teardown—brought to you by Becky Stern & PoD.

Today, we took apart a Philips Sonicare kids’ electric toothbrush. The short story? It’s made of metal and plastic. The long story—well, keep reading (and watching) below. Also, click here if you need your own—no commissions, sadly.

Tools & Techniques
To deconstruct the toothbrush, I used (1) my hands (2) a tiny screwdriver (3) a less tiny screwdriver (4) a wire cutter and (5) brute strength. The larger screwdriver was required as a lever to remove the plastic outer base of the brush, as well as dislodge both the control board and Li-Ion battery from the plastic skeleton. The tiny screwdriver was used to separate the oscillating brush head, cam, and gears from the shaft (which also held the motor).

Toothbrush teardown timelapse

Notable Design Elements
(1) It’s probably no surprise that Philips has made the Li-Ion battery next-to-impossible to remove. While electric toothbrushes are rechargeable, the battery will eventually run out, and if it does, you’ll need to buy a whole new unit. There’s no feasible way to replace that battery yourself. That being said, lithium batteries can be dangerous to handle, which means that until they are safe to handle, they should be kept as far out of reach (and replacement) as possible. In which case, a job very well done.

(2) I found myself contemplating the size of the removable toothbrush head. This, of course, is the “consumable” element of the product; the Philips website states that it is “recommended to replace your Philips Sonicare Brush Head every three months of normal use.” Looking at the inner underpinnings of the brush head, I wondered if the replaceable component could be reduced to just the very tip of the brush (just the brush, and no upper shaft), thereby reducing the amount of plastic. However, even if technically possible, Philips would almost certainly ignore this efficiency, because it would imply charging less for their brush replacement packs (a set of three currently retails at $31.96$42.96).

Electric Toothbrush: Parts

Electric Toothbrush Components & Materials:
1 – Toothbrush head (plastic + nylon for bristles—most likely Nylon 6-12)
2 – Outer case (plastic)
3 – Charging coil (copper)
4 – Induction charger coil (copper)
5 – Oscillating brush head + cam/gears (steel + plastic)
6 – Screws (steel)
7 – Motor (aluminum + copper)
8 – Torsion bar (steel)
9 -Magnet (iron, nickel, cobalt, +/or steel)
10 – Shaft, cam + gears (steel + plastic)
11 – Circuit board (copper, fiberglass, resin)
12 – Power button cover (plastic)
13 – Button cover / thumb grip (plastic)
14 – Lithium (Li-Ion) battery (lithium, nickel, cobalt, possibly manganese)

Electric Toothbrush: Circuit Board

Circuit Board Components:
1 – Power button
2 – Programming pads
3 – Coil connections
4 – Chip (#CY8C4247LQI-BL483)
5 – Diode bridge

Chip details
– Type: ARM Microcontrollers – MCU PSoC 4 BLE Integrated Chip; see data sheet
– Manufacturer: Infineon Technologies
– Price: $7.75 (for 1 unit)

Manufacturing techniques & equipment

  • Outer casing: These plastic elements are made from plastic granules, shaped while hot in molds along an mechanical assembly line. A computer scans the casing to ensure there are no flaws, and rays of UV light are blasted to make sure the plastic is completely sterile.
  • Head and bristles: Bristle color determines thickness (influencing the location on the center or perimeter of brush head). A machine inserts the bristles into holes in the plastic head by folding them around tiny pieces of wire. A blade cuts the tips of the bristles to ensure they’re all the same length, then blunts any sharpe edges. The necks are then attached the the brush heads.
  • A machine clamps the gearbox (cam + gears) and motor together. A worker then manually melds them together with the lithium battery, then plugs them into a charging unit to ensure the circuit is connected.
  • The inner components are then fitted into the casings via machine assembly.
  • A machine then seals the plastic bottom of the casing with a twist.
  • A quality controller gives them a final human review, while a subset of the batch are sent off for quality testing (performed by a machine). If that goes smoothly, they’re off to consumers!

Maybe we should all just be brushing our teeth with our fingers?