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

We use ProtoParts (USA / China) for prototypes. Especially larger
quantities we can't realistically manufacture ourselves.
Nearer Home, there's also Product Dev (Christchurch), might be worth a look.

I like the idea of standard pipe for the body & just get the end caps etc
printed / molded.

Re print material, I've never been real happy about PLA - I find it
brittle. I tend to use ABS as 'standard' and PC where extra strength or
flexibility is concerned. (The PLA problem may be down to using old
material ?)

RP

On Thu, 9 Apr 2026 at 10:14, Brent Brown <[email protected]> wrote:

> Another great project!
>
> Measuring a piece of DN40 DWV PVC tube lying nearby... ID is 38, OD is
> 43mm. A
> 5.8m length for NZD19 from trade depot would break down to maybe 47 or 48
> pieces of 120mm @ ~NZD0.40ea. Food for thought, though I can't imagine you
> haven't had this thought already :-)
> https://tradedepot.co.nz/upvc-dwv-drainage-pipe-40mm-x-6m/
>
> Additionally/alternatively wondering if this plastic component could be
> "crowd
> sourced" by "makers" with 3D printers at home. E.g. use PLA material
> (cheapest/easiest) but over engineer to get the mechanical qualities
> required, a
> community of volunteers each prints a bunch of say xx or more pieces at a
> time and
> donates material/time/shipping to the cause. Or perhaps give them a free
> reel of
> filament and they return a percentage of it in printed parts.
>
> I like the idea of no transparent end cap as lesser parts count has
> merits, and rely
> on internal lens... secondary lens might be a struggle to improve light
> characteristics
> and soak up lumens or milli-lumens that you don't have in abundance. That
> said, a
> degree of sealing may be a consideration you haven't mentioned yet.
>
> I imagine this thing is fixed/hung high up and the light will point
> straight down?
>
> Brent
>
> On 9 Apr 2026 at 3:43, RussellMc wrote:
>
> > 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/
> > --
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