[TECH]:: Advice sought on 10 and 000 quantity manufacture of tubular plastic products

The following is from posts to Stack Exchange and Facebook engineerings
groups.
I'm sure that there are people here just as capable :-).
Main concern is suggestion how to manufacture 1000 and 10-20 tubular
plastic items at low cost.
I'm asking Chinese and local manufacturers these questions.
Local manufacture has minimal chance of being viable, sadly.

     Russell
_______________________

I'm looking for advice on

How to make the following in quantities of:

   - Prototype (10-20 volume)
   - Small volume (say 1000) <-- this is the main concern

For larger volumes plastic injection moulding is liable to be most economic.

   2.

   Order of cost for labor (labour to me - I'm a Kiwi)
   3.

   Thoughts on material choices.

In volume production (and maybe 1000 quantity) a mounting "foot" will
probably be added.

This is a light for use in women's toilets (initially) in refugee camps.
The light level is VERY low but vastly better than utter darkness, and it
will operate from a single Alkaline D cell all night for 5 years.
An optional version with a PIR person sensor allowing brighter light only
when occupied.

Target cost is $US3 (or less) complete (electronics, housing, battery).

Ideally the device would be highly theft and vandalism resistance BUT this
is probably unachievable given cost constraints.
Metal is not an option: ANY metal parts are liable to be removed for
"recycling" :-( . At least for the prototype and maybe the first 1000
lights durability and vandal resistance are not a major factor, although eg
PLA plastic is probably not robust enough.
------------------------------

3D printing may be acceptable for the first prototypes.
I have 3D printing facilities. PLA filament and Resin printers at present
but strength is very poor. ABS filament and carbon fibre filled resin MAY
be an option.

I have a lathe, milling machine and router and may yet chew the prototypes
out of tube and sheet.

Diagram shows possible plastic choices but other suggestions welcome.

A, B: Body and end cap ABS PC PE ... Black (ideally) opaque.

C, D: "Lens" (just a light "port") Actual lens is internal.


*Diagram is just to convey concept.Dimensions shown are conceptual only and
need work.*
Some parts are too thin. TBD.

Please excuse bad diagram - after too long away I'm learning a new graphics
package and this was quicker :-) :-(


*Diagram here <https://i.sstatic.net/GkUWD6QE.png>(Stack Exchange):  *

*And here (Dropbox)
<https://www.dropbox.com/scl/fi/3ldxj6zl4x2sfpak4v4oj/5YL-body-design-conceptual-Cambrian-prototype-dimensioned-V321-FF.jpg?rlkey=r84hgb7mr3c1i2skkd6hhwq1k&dl=0>*

C & D are both transparent.
*Ideally D is not needed and C fits as a cap on A.*

In volume C&D can be one part but that's harder in small volume.

A-B join can be permanent.
C-D pinned / grub screws / thread / magic.

Ideally opened maybe twice at start of life.
Thread may be nice but not if costly/hard.

Adhesive use acceptable.

BONUS if C & D pass IR light well - allowing PIR to work inside and not
need a custom "port" for its lens.

Acrylic/PMMA - good light transmission.
Not robust.
Polycarbonate - slightly less light transmission. Robust. Expensive.
------------------------------

Manufacture:

3D print
"Screw machine"
Other ... ?

Also on: https://www.facebook.com/share/p/14ZCy9T4FVv/