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

On Thu, 16 Apr 2026 at 03:48, Allen Mulvey <[email protected]> wrote:

> The lights below are tap on/off, sorry.
> Here is the motion activate light ($2.38 each):
> * 8 Pack Motion Sensor Light Indoor, Closet Light
> <https://www.amazon.com/Wotermly-Cordless-Battery-Powered-Stick-Anywhere-Bathroom/dp/B09MCJ52Z2/ref=sr_1_49_sspa?adgrpid=1337006701093366&dib=eyJ2IjoiMSJ9.Or5-oyk108X56l1vZFoq8g_3bdsHboS8urBumrqUxHxktSYnEbOLxwpETKpYeCjsJfLf68grsOBpB6poVuEdjR6fLsyURNT-xAVAaCnneNo.mOC5wv7KBY2olqRqKJuKaxnb5kxwSdW2WfltfxtRNL8&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=1776267669&sr=8-49-spons&xpid=maQBeVsgrNjsx&sp_csd=d2lkZ2V0TmFtZT1zcF9hdGZfbmV4dA&th=1>*
>
> Is this something like what you are trying to do?

Conceptually sort of maybe.
Thanks for the links.
That light is an excellent start and probably does what it does well.
The gap between that and mine appears smallish. It's not. Sadly.
My targets  / specs include:

Operate all night always on for 5+ years inside refugee camp latrine
building.
Africa and other. Resist ammonia, temperature, "recycling".
PIR option same 5 years but either dimmer/brighter or off/bright.
PIR option runs in 10-20 uA range quiescent.
Non PIR option under 10 uA quiescent.
Vandalism resistant.
Theft resistant.
Unattractive batteries (D cell, spot welded connections)
IP_high/high

3 x AAA give equivalent of a single cell at about 4Ah at < 1 mA
1 x D gives 18 Ah.
D needs boost converter (> 80% across range) so say 14 AH effective.
So D vs 3 x AAA is 14/4 = 3.5:1.
Say 3:1.

Target cost with battery in large volume (which may never happen) is $US3.


  Russell








>
> Allen Mulvey
>
> On 4/15/2026 11:36 AM, Allen Mulvey wrote:
> > 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/
> --
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