Plastic Injection Moulding Specialists. Est 1948.

Brief

The brief was to design a chiller door handle replicating the packaging design of the Sunny Delight product.

CAD Component Design

CAD drawings submitted for client approval were sufficient for the client to OK the manufacture of prototypes.

Manufacturing

1 . Replica bottle in clear polycarbonate – front half only, open at top and back.

2 . The lid moulded with the bottle in the same material.

3 . Mounting bracket punched and formed in steel, finished in black polyester powder coat. Component mounts the handle to the door of the chiller. It provides strength for the handle when the moulded front is screwed to it. Lid is positioned last, linked to the bracket by a screw passing right through both components.

The plastic parts of the prototypes could not easily be made from polycarbonate, the proposed production material. the nearest alternative material was used. This was P.E.T. which had the necessary clarity and was easy to vacuum form into the shapes required. Vacuum forming moulds were made, for bottle and lid.

Our metalworking department was producing samples of the mounting bracket, which for the prototype was sprayed black.

We were thus able to deliver prototypes in ten days from receipt of order. Once approval of prototype was received, design and manufacture of the injection mould for bottle and lid was planned. The completion of the job being the production of the mounting bracket. This last process was straightforward as the C.A.D. – C.A.M. details were already available from the prototype.