The objective of this project was to create a mockup of a hand-held object. The teddy bear is a fun toy that many children play with regularly.
After converging upon approximate relationships and a general shape with ideation sketching, a Solidworks model of the bear was created using hexagonal and rectangular features. This shape was then put into Pepakura software, which generates a pattern to cut out to assemble a shell. Using wood glue, the laser cut shapes were assembled into two pieces: a head shell and a body shell. These two shells were then filled with expanding foam to make a hard foam core for the final model. Industrial non-hardening clay was then applied to half of the foam core and molded to include stitching details and improved curvature.