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

I was going to make this a new post but have added it to my prior one.
I am trying to manufacture say 1000 items in China.
"*The problem*" [see below] *is not so much manufacturing costs per se but
how to achieve manufacturing at acceptable cost at this scale, in a far off
land without the usual economies of scale and ability to manage results.*

*Past history:    *I have experience with manufacturing hundreds of
thousands of items, maybe tens of thousands of one item minimum. (My
electronic designs and substantial mechanical input). (Someone else's
product and money.)

When you are working at that scale you can travel if needed (and it IS
needed).
You can hire quality assurance inspectors (also needed).
You expect as of right to have Chinese designers available as / if required
either to implement defined requirements fairly fully or cooperatively.
(Injection moulding, PCB manufacture, parts sourcing, mechanical-
electronic integration, testing, ...) . At our hundreds of thousands scale
involvement of "European" Chinese market manufacturing experts made
economic sense. Overall you get a variably cooperative team effort.
(Everyone wants things to work out - not all have your priorities).


These are the small tubular housing lights that I have mentioned recently.
(details below)
The manufacturing method is NOT the main question here. But past and any
ongoing input is most welcome.
At 1000 almost enough for plastic moulding. Almost.
Current most promising direction is existing plastic tube, custom minimum
cost end caps, flat PMMA of PC lens held by end cap.

*The problem:*

*How to achieve China manufacturing at lowest reasonable cost for say 1000
volume of the product I mentioned.*

Basic pricing can be determined by combining various quotations (solicited
and online), and website costs. 'The problem' is how these relate to an
actual factory door or shipped real product.

I can price molds, moulded parts, PCBs, assembled PCBAs.
I can estimate assembly times.
I can estimate costs for eg snap on end caps to tubes, tube stock, "lenses"
... .
BUT someone has to turn all the bits into a boxed product.
Integration. ... .
Obtain/combine/pack/ship: Battery, housing pieces, PCBA, combining,
testing, QA (yeah right), boxing, shipping.
At 1000 quantity this is/appears to be a formidable task.
And hard to cost

All comments welcome.

____________________

It just occurred to me that someone like Sparkfun or Adafruit industries or
similar might help.
The product has the potential to have far wider application and may be
worthwhile to them as a "free" product design.
One can hope :-).

I am looking at a few other options.



         Russell
         +64 9 21 116 5485

        Messenger     @rus.el.16
        Microsoft teams
        Skype russellmcmahon (not used recently)






On Thu, 9 Apr 2026 at 03:43, RussellMc <[email protected]> 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/
>