[GreenKeys] OT: Those damn packages...

[jangus at suddenlink.net]

Roy Morgan <k1lky at earthlink.net> wrote: 
> On Jul 23, 2010, at 12:46 AM, Jeffrey Angus wrote:...
> > I almost hate to admit it, but you know those awful blister pack
> > packages ...Yes, I'm the AH that did the patterns for them for a
> > vacuum forming shop.
> 
> GOODness.  Those things are produced all over the world, are they  
> not?  Latest ones here were for a Barbie mini-doll bought at Target.   
> Nearly impossible to get open.

Produced worldwide, but there's only a hand full of prototype shops
that take a badly drawn sketch and turn it into a manufacturable pattern.

Several levels of evil too: Typically made with 0.020" PET clear plastic
1. Blister pack. Usually just glued to a cardboard backing.
2. Folded blister. The edges wrap around the cardboard.
3. Clam shell. This requires a mating back that is usually welded to the front.
4. Clam shell with foot. Reverse taper foot on the bottom for self support.

The stores set up their shelving with a "planogram" that details the actual
size of the package. That's the bottom line as to how big it can be.

Trying to explain draft angles or allowances for the seam around the edges
to graphic artists is a full time and very frustrating process. 

Of course, the most fun part is watching the artists toss an idea around right
up to the last minute then handing you a sketch with "needs to be 6" x 12"
and we need 20 samples by Friday." (this usually happens on Wednesday)

The prototype patterns are made from a combination of MDF plexiglass (for
the base), styrene and bondo. Once approved, the prototype patterns are
sent to the manufacturer and copied in aluminum as master dies for up to
40 packages at a time.

6 months down the road, it is sitting on your kitchen table defying you to get
it open without hurting yourself or the product inside.

Not that I really am a sadistic curmudgeon, but I do take a certain amount of
pride in my ability to take a crude drawing and turn it into a finished master
within 18 hours.

Equally satisfying is designing a housing for a special project and creating
the patterns for the original vacuum forming of 0.125" ABS, but also the
various templates and fixtures for tooling to turn the rough shape into a
finished product. "Suitable for framing" as they say. ;-)

And just so you don't think I'm totally lacking in any redeeming values, I also
make patterns for replacement dial covers for antique radios.

Jeff-1.0
wa6fwi
 
--
Fox's Mercantile, Ranger TX