Modular Animal Toy Design

I’m developing a line of plastic animal toys for children aged 4-7. Each figure breaks down into a head, body and four legs that all share the exact same connection geometry, so kids can mix a lion’s head with a giraffe’s legs and an elephant’s body without any wobble or gaps.

I need this concept turned into manufacture-ready files for a collection of 10 different animals. The joint system should combine a small molded hinge with an integrated pocket that holds a tiny magnet, giving each piece a satisfying snap while remaining easy for little hands to separate. Every part must respect one common size envelope to guarantee full interchangeability and comply with standard child-safety requirements for that age group (smooth edges, no swallow-hazard components, durable food-grade plastic, etc.). Experience with snap-fit design, tolerancing for injection-molded plastics, and safe magnet selection is highly relevant.

Deliverables
• 3D CAD models in STEP/STL for every unique part
• Exploded and assembled renders for visual reference
• Bill of materials listing plastic grade, magnet spec and hinge pin details
• Brief test notes confirming fit, pull-force and safety clearances

Any mainstream CAD platform is fine as long as the output is tooling-ready. Please share examples of similar modular or magnetic toys you’ve created and outline your proposed workflow for keeping dimensions consistent across all interchangeable parts.