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

These are available retail on Amazon for $3.50 each:
Energizer LED Tap Light 
<https://www.amazon.com/Energizer-Operated-Wireless-Portable-Lighting/dp/B01MS5KXJ4/ref=sr_1_34?adgrpid=1337006701093366&dib=eyJ2IjoiMSJ9.AErwDwRj-lx_zJUGdbGaNqD2IcAM4y_pSrUtYe_iUEWlUdRqDPBl7Bb1ECrqWIC4FEziMrtjpIWLz11BnAp5TJgLwregFdLy3X91ZsXNFB3W9v_YGx1fXeNfguO2HAdORXLd8w_u0DSKocNZZoUZoSTlMM0SvF-Iju91loxf9cSdqN4le6lWGi65mk0db4pQBdvA7Bx3f03AHbTdfun8gUKzh8aXCAdjnh1w19A7faAfDkzawZ8-oowAVrDOKI44BOi9gEWVOT89SThpm0RwvwgrrW9Q4CtaDw7uIlMOIbE.zAai1roQajp0YkLiPrpDaVrfe8IAcyxM2YD1CPF6PZw&dib_tag=se&hvadid=83562989607729&hvbmt=be&hvdev=c&hvlocphy=105463&hvnetw=o&hvqmt=e&hvtargid=kwd-83563254215316%3Aloc-190&hydadcr=6925_10447791&keywords=battery%2Boperated%2Bnight%2Blight&mcid=a7840eb039a93f659284ce3df0040edb&msclkid=057b15725c351b8b94047cadf29a3b98&qid=1776266947&sr=8-34&th=1>

Is this something like what you are trying to do?

Allen Mulvey


On 4/8/2026 11:43 AM, 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/