I was awarded a US design patent for a portable cooler like those
taken to the beach or on picnics. The design is for a hard plastic
cooler with an inner removable basket. I'm looking for a company that
would make the coolers for me. I would then market and distribute
them myself. To assist your search, companies such as Rubbermaid or
Igloo
should not be targets of your search since they would either want to
license or purchase the patent from me. I'm looking for someone to
simply
build it for me. I'm planning to have about 100 to 500 made. All
possible manufacturers should be identified. Companies that deal with
plastics, plastic molds and insulation might be possible resources.
 Thank you, Ted Markus

Ted:

	Congratulations on your patent! That process in itself is arduous.

	As I am sure you are aware, with only 100-500 units being made the
cost per unit is going to be very high. The up front costs of making
the molds needed for each of the plastic parts that go into your
invention may be prohibitive, but would pay for themselves, obviously,
should you order thousands more through the same manufacturer.

	Perhaps you might want to consider Stereolithography.
 
From: http://www.stereolithography.com/slainfo.php

 Stereolithography (SLA) is a "rapid-prototyping" process which
produces a physical, three dimensional object from a 3D CAD file. A
stereolithography machine uses a computer controlled laser to cure a
photo-sensitive resin, layer by layer, to create the 3D part.

Many companies like to use SLA to produce a prototype that can be
handled, and tested to look for design flaws not inherent in the
original drawings or models. Many manufacturers offer this service, or
you can have it done yourself at various SLA shops. You will need a
CAD drawing to generate a SLA model.
Once you have the SLA model have your plastic parts for the cooler
produced with urethane casting or injection molding.

This company handles the SLA model all the way through to the final
product. They are located in Wisconsin.

Advantage Prototype Systems

http://www.advproto.com/urethane.htm

Here is another link to get a quote on a SLA model, from
Sterolithography.com:

http://www.stereolithography.com/quotes.php

Here are a couple of other companies that offer injection molding and
SLA models.

http://www.jlmolding.com/index.html

http://www.arrk.com/Services/services.html

If you don’t have CAD drawings, this company will create them for you
and follow through with the rapid prototype. They are located in
Largo, FL.

http://ventelplastics.com/design_et_al.htm

And some more:

http://dir.tpage.com/16/25/

http://www.ttmp.com/main.html

http://www.newenglandmolders.com/

http://www.plastiform-inc.com/technologies.htm

This site has a fast turn around, and seem to be inexpensive.

http://www.protomold.com/

http://www.jdimolds.com/html/ind_app.html

This company specializes in small production:

“On-line Instant Quotes using your uploaded CAD data right here on our
Website. You upload your data, choose a low-volume production method,
then instantly receive a binding quote for the manufacture of your
project.”
http://www.quickparts.com/index.asp


“Prototyping. Rapid prototyping processes are great for testing form
and fit, but many times FDM, SLA and the others are no substitute for
testing with real injection molded parts. With Protomold, you can get
prototype injection molded parts for as little as $1995 and in as
little as 5 days (for a premium). Fast and cost effective enough to
fix problems if the first design is not quite right. (I know, this
never happens!)”

Another thought is to go to a sourcing portal, like MFGQuote: Here you
can upload  some sketches of your cooler, and specs, and
theoretically, get multiple quotes.

http://www.mfgquote.com/manufacturing_disciplines/mfgq/ggle_custom_plastic_injection_molding.html

Here is another portal:

http://www.toolanddiequotes.com/


Season International is based in Canada but has locations around the
world, six of which are in the USA.


http://www.seasoncom.com/offices/offices.htm

From Season International:

“What do I need for a quotation? 
Detail part drawings in electronic data is preferred. Otherwise, blue
prints are required. Samples are helpful but not necessary as
measurements and other information to complete the quote is derived
from the drawings. Detailed information includes; material of the mold
and the plastic parts, number of cavities or volume per production,
surface finishing and specification of the molding machine.”


Insulation:

	If you already have an idea what material is to be used to insulate
the cooler it will be easier to find providers/manufacturers. Please
ask for a clarification and I can find a plant that can do this with
your plastic parts . the Thermal Insulation Association has a great
listing of all the available type of insulation. You can find it here:


http://www.insulation.org/pages/rl_thermal.html



I hope this points you in the right direction. There are literally
thousands of companies that will produce your design, without touching
your patent.

Please feel free to ask for a clarification if you have any questions.

Sincerely,

Colin




Google search terms:

plastic injection molding custom work
plastics man

---

Request for Answer Clarification by theo1-ga on 29 Jun 2002 18:01 PDT

Hi Colin,
Your answer to my question was impressive. I've been very busy since
last week when I sent it and have had time to only scan some of the
resoures you provided. I'll really need to study it more
thoroughly.It's a little overwhelming at this point. Initially, I have
a few questions but I'll start with just one. What's a 3D CAD file?
I'm not familiar with this. I'm guessing it would be a computerized
drawing of the cooler? Could you clarify, please.If that's correct,
other than one of the companies you've noted, how would I go about
getting one. I have an illustration of the  cooler that was done on a
computer that is 3D. Could this be utilized?
Also, did you have any "favorite" companies or websites that appear to
be user friendly for a one time inventor such as myself? Is this an
area you're familiar with or are you in virgin territory youself?
You're anwer gave me the impression that you might have some technical
training.
Thanks, Ted

---

Clarification of Answer by colin-ga on 30 Jun 2002 07:36 PDT

Ted:

Yes, you are correct the 3D CAD is a 3 dimensional Computer Aided
Design of your product.

Here are some sample 3D images:

http://www.cadforum.com/3dimages/3dimage3.asp

Can you use your 3d Image?

That depends on which CAD program was used to create the image. The
program that created the file needs to be able to output a specific
file type “STL” (at least for this company, quickparts.com). If the
cooler picture was called cooler.jpg or cooler.gif, when you save the
drawing as, our convert it to,  an STL file, it will be called
cooler.STL

This is the file they need for rapid prototyping.

Programs such as Mechanical Desktop, Auto CAD or SolidWorks will work.

For a description of STL files, and how to output STL files on various
CAD programs see this page:

http://www.quickparts.com/encyclopedia/stl.asp


I have not used these services before, but I like the looks of two
firms:

Quickparts: They specifically mention low volume production, which is
what you need. I like their “instant” and “quick” quotes. You will
need the cooler in STL format as described above, but you can upload
it (send it to their website) directly from their web page. You can
(once registered) get an instant quote just from that STL file.

http://www.quickparts.com/info/aboutus.asp


VenTel Plastics, in Largo, FL: This company has been in business since
1982 and can handle every aspect of you production. If you cannot
generate a STL file from your 3D drawing, VenTel can do it for you.
Their services include drafting, prototyping, manufacture and even the
final assembly of your product.


http://ventelplastics.com/index.htm


	I hope this clarifies your questions. The first step you should take
is to ask whoever drew your 3D illustration if they can output a STL
file. If so, you are in luck and save drafting fees.
After acquiring your STL file then you start shopping. I am sure you
will find a wide array of prices.

Best of luck,


Sincerely,

Colin




Google search terms:

plastic injection molding custom work
plastics manufacturing insulation
CAD 3D drawings

This answer has provided me with both information and leads to further
the process of development of my product. A job well done.

Ted,

What you seem to be looking for is an Industrial Designer or an ID
firm. Our job is to take existing ideas or generate new ideas, and
develop them. An Industrial Designer often has broad engineering,
manufacturing, as well as design experience. I will use a current
project as an example. I was contacted by a toy company who needed to
come up with a fresh look for there products. I first did research to
get an idea of how there products are currently used, look over
competitors products, and then determine what the new toys would look
like with sketches. After a while of this, we are left with a few
concepts. This is when we begin the 3D modeling stage. These models
are built to the exact dimensions of the final product, and are easily
modified as changes come. The model also helps us with the function of
the parts. We are able to test assemblies and do structural analysis
with these models. They are also used by many customers to generate
realistic renderings for marketing and to acquire financing from
investors. As mentioned, these models can be used with a rapid
prototyping process, which will make an actual part for visual and
real world testing. I would, in your case, not recommend this process
to you, since it is very expensive.

For you're product, I would recommend using thermoforming of plastic
to create the skin of your cooler. Injection mold tooling should only
be considered when making 10,000 or so parts. Thermoforming tools can
be made for as little as $100 and short runs are welcome. The
insulation, for prototyping and some production purposes, would be
from a two part foam system. Closed cell foam is the most widely used
insulation in coolers.

I hope this helps.
S. Seelye

Ted,

You can also try offshore companies that use the technologies
described in the answer. I'm sure it will be more financialy feasible.
If your product sells in great quantities, and you need good quality
injection molding tools, I would like to recommend our injection mold
making services. You can learn more details on our website <a
href="http://www.dukheung.co.kr">on plastic injection molds</a>