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

Sorry, I missed the 5 yr part. That makes a huge difference. If anybody 
can meet the challenge, I'm betting you will.

Allen Mulvey

On 4/15/2026 12:21 PM, RussellMc wrote:
> 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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