Invention of a New Toy Technology

When challenged to enhance toy functionality using smartphones without incorporating any toy electronics, I invented a breakthrough technology that unlocked immersive experiences previously unheard of in Happy Meal toys—achieving a level of product engagement that, until now, had been impossible.

This innovation drove a $100M lift in promotion performance and led to the formation of a new company division, now over 100 employees strong, dedicated to advancing digital integration in toys.

From Concept to Reality

Faced with the challenge of integrating smartphone functionality into toys for Ron’s Gone Wrong, expectations were initially modest: use basic light-pipe technology to transmit a single color of light from the phone screen into the toy. But I envisioned a more immersive and dynamic experience—one that used lenses and mirrors to internally project animated images directly onto the surface of the toy.

To prove this ambitious concept could work, I taught myself ray-tracing software to communicate the assembly to our sculptors and engineers in Asia, collaborating with them to create a functional prototype.

Although technically successful, the prototype was not yet resonating with the executives whose support was crucial for moving forward in this radically different direction. It was clear the technical demo was lacking emotional impact, so I created a demonstration of the app to align stakeholders behind a comprehensive product vision.

This demo featured the toy’s face animating and talking directly with the user throughout a variety of experiences, showcasing its potential for deeply personal interactions. This resonated deeply, with executives aligning behind this vision as the clear path forward. Soon after, a patent application was filed for this technology.

Cost-Saving Innovation

Delivering the projection feature within budget constraints required innovative cost-saving solutions for the toy’s mechanical components.

By reimagining a new *twist* on classic band-powered mechanisms, I unlocked the use of bands to power HM toys for the first time in history. This enabled us to deliver pull-back functionality at a fraction of the cost of a gearbox, preserving the projection feature.

This custom band mechanism has since become our new standard for powering movement.

An Impact Beyond
our Wildest Projections

When the movie was delayed two months beyond the already-locked launch date of our toys, expectations were that this program would significantly underperform.

We could not have been more wrong.

The Happy Meal App achieved over 1 million downloads in the first month—a 6,000% increase compared to prior programs—and topped the family app category in the App Store.

Even without the movie’s release, restaurant sales surged by 20%, driving an extraordinary $100M lift in Happy Meal sales.

App Downloads in First Month

Shaping the Future

The breakout success of Ron’s Gone Wrong was an undeniable declaration of the potential behind using smartphones to drive and enrich the physical toy play experience.

It has since led to the formation of a new division within the company, now over 100 employees strong, dedicated to creating digital tie-ins for every Happy Meal program. 

This product line was a key that unlocked the possibilities of connected play, becoming a template for intuitively integrating digital elements in a way that captivates, and paving the way for even more immersive experiences to come.

Up Next:

Portfolio

An overview of my product development work.