Case Study: Mega Bloks achieves die-cast realism for a curvy rally car toy with 3D Systems (Geomagic)

Mega Bloks Uses 3D scanning and Geomagic To Design Toy That Replicates European Rally Car

Mega Bloks, one of North America’s top 10 toy brands, wanted to design a curvy European-style rally car with die-cast level realism while staying true to its trademarked, geometric building system and avoiding licensing issues. The challenge was to create a recognizable, detailed shape that respected the limits of the company’s block-based construction and could be approved quickly without lengthy CAD development.

The team sketched the design, sculpted a half-clay model (mirrored for symmetry) and used Creaform 3D scanning with Geomagic reverse‑engineering and traditional CAD/CAM to generate a Class‑A surface and precise digital model. This workflow preserved dimensions, prevented blocks from protruding through fenders, eliminated clay deformation, cut development time from months to hours for shape changes, and produced a perfectly scaled, realistic rally car toy.

Mega Bloks

Yanick Tremblay

Design Coordinator