My company manufactures LED tail lights for motorcycles. Until now, we have been making "retrofit" kits that go in an OEM tail light. But we want to be able to do a complete assembly.
Check out these pictures
http://i7.ebayimg.com/01/i/05/8c/8f/8e_1.JPG
http://i19.ebayimg.com/02/i/05/8c/9d/12_1.JPG
The black portion is ABS plastic, and the front is clear acrylic/PMMA. We currently sell these to various distributors, but if we can mold a complete light, we can sell about 5 times what we sell now.
I have a CNC bridgeport and I am very confident in the theory of molding, but I've never tried to make a mold. The problem is we have about 6-7 lights we want to do, but the OEM's change them up every 2-3 years, and so our total quantity would only ever be 1000-2000/yr and probably never more than 5,000-7,000 of any given light.
As I see it, my options are
1) Machine molds myself out of 7075 AL and pick up an injection molding machine to make the parts. I dont so much have a problem doing this but I know there will be a learning curve. On a difficulty scale, how would this part rank to make? I do not need to worry too much about the actual lens design because it uses LEDs and we do most of our optics in the LEDs and their lenses, so the outer lens doesnt need to be perfect. I would probably just do a bunch of "pyramids" on the inside and a glass-smooth surface on the outside
2) Outsource. I know others are paying $2k per mold to get these made in Taiwan/China in Aluminum. I would prefer to keep it in the USA though. Also, I dont know if I can get that price since I dont have contacts and a history of volume - what do you all think?
3) Use one of those short-run/proto shops in the USA. I dont know what the cost would be - probably more than offshore.
4) Team up with someone who can do the molding, and let me do the electronics, sales and distribution, and try to get it done quicker that way. Basically someone who would cover the cost of making the mold (CAD/CAM and labor to make the mold) and I could cover actual materials cost, and I could pay a higher per-part cost until the initial labor costs were "paid off", plus a bit more to sweeten the deal and make it worthwhile to the person doing the molding.
I am hoping to be able to find a way to do option #4, but I have a feeling its gonna be tough to find someone to work with in that fashion, especially considering the number of tire-kickers who always want something for nothing, etc, etc.
Does anyone have any ideas? Based on the pics, what sort of tonnage/shot size machine would I be looking at? The light could be held in your hand - its smaller than a car tail light by a little. Is acrylic and abs tough materials to mold? I have a CMM so I can mount up the light and generate a step or igs file, but I am not knowledgeable about where to place runners, vents, and anything about actually running a mold.
ANY insight is greatly apprecaited!
Thanks,
Mike