What if you could add light and sound to LEGO-style building blocks? That’s the idea behind Buffalo Grove, Illinois-based E-Blox. Founded in 2016 by Art Seymour and his sons James and Joseph, their patented technology is, well, electrifying the educational toy market.
E-Blox’s plug-together Lego-style bricks and modules allow kids to build almost anything they can imagine: a robot with flashing eyes, a toy pet that makes sounds, even a working FM radio. E-Blox offers three different interactive building block product lines, all of which provide the foundation for a STEM education, with specific products for the STEAM and STREAM markets as well.
Milling Technology for Precision Prototyping
E-Blox Senior Designer Brian Johnson joined the firm after working with Art Seymour for more than 20 years at another educational toy company. “I knew I needed a new prototyping device,” said Johnson. “I had been using 3D printers but the results were not what we wanted – the accuracy was not there.”
After researching and testing subtractive milling devices from several manufacturers, Johnson chose the Roland MODELA MDX- 50 benchtop milling machine. “The MDX-50 is the perfect size and the fourth axis is a real timesaver,” said Johnson. “Most importantly, it provides the high level of accuracy we need for the blocks.”
Johnson found the MDX-50 to be extremely user-friendly. “The learning curve was minimal–it’s simple to operate. Once I had the basics down, we were off to the races,” said Johnson. In addition to prototyping in ABS, polycarbonate and acrylic, Johnson has used the mill to create wooden mold forms.
The mill sits just outside Johnson’s office for easy access. He notes that having milling capability on-site has dramatically improved the company’s speed in turning new ideas into new products.
“We can get a new product turned around in a month or two. Prior to acquiring the MDX-50, we had to wait many months to get prototyped items back from China or elsewhere,” said Johnson. “Now, with our prototyping on-site, I can release the product to our manufacturers as soon as it’s ready.”
Prototypes That Perform
To create a prototype, Johnson first designs the product in SolidWorks. He then uses the included CAM software to mill a prototype on the MDX-50. Next, he adds the printed circuit board layouts and mills out various plastic parts. The parts are then tin-plated for conductivity, using a non-toxic, patented process. The process allows for circuits to be built in the X, Y and Z direction and eventually be paired with a 9v battery.
Most of the products Johnson mills start from blocks of material that are less than two inches square. He can mill two assemblies at a time, typically with six parts per assembly.
To make his prototypes functional, Johnson needs accuracy to within 5/100s of a millimeter. “The MDX gives me accuracy to within 4.85 millimeters, every time,” said Johnson. “Its precision and consistency allow me to take actual LEGO blocks and bring them into the design.”
Johnson is currently prototyping clear Lumen minifigures out of polycarbonate and and ABS, as well as a clear AFX soundblock made out of acrylic. “Especially with minifigures, accuracy is paramount. These are intricate parts,” said Johnson. “The prototypes we mill work so well, I can take them to the trade shows and show them off.”
Growing the Business
E-Blox is housed in a freestanding 20,000 square foot building and warehouse, and their business is growing every year. E-Blox clients are primarily retailers, with a growing cadre of education market outlets.
“Retailers and teachers are eating it up–they are always looking for products that let kids have fun while learning,” Johnson said.