[GreenKeys] OT: Those damn packages...

[Richard M. Gillingham]

Really interesting Jeff, Thanks.
73
Gil, W1RG
----- Original Message ----- 
From: <jangus at suddenlink.net>
To: <greenkeys at mailman.qth.net>
Sent: Saturday, July 24, 2010 7:39 PM
Subject: Re: [GreenKeys] OT: Those damn packages...


> 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
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