Design and Technology – Resistant materials | e-Consult

Here's a discussion of three manufacturing methods suitable for mass-producing reusable water bottles:

1. Injection Moulding: This process involves injecting molten material (typically plastic like polypropylene or Tritan) into a mould. Advantages include high speed of production, ability to create complex shapes, and good dimensional accuracy. Disadvantages are the high initial cost of the mould, potential for waste material, and limitations on the types of materials that can be used. It's particularly suitable for high-volume production due to its speed.
2. Blow Moulding: This method is specifically used for hollow plastic products like bottles. A parison (a hollow tube of plastic) is inflated inside a mould with compressed air. Advantages include relatively low tooling costs compared to injection moulding for hollow shapes, and suitability for a wide range of plastics. Disadvantages can include imperfections in the surface finish and potential for uneven wall thickness. It's a cost-effective option for large-scale bottle production.
3. Extrusion: This process involves forcing a heated plastic material through a die to create a continuous profile. The profile is then cut to length. Advantages include continuous production, suitability for producing long, uniform shapes, and relatively low material waste. Disadvantages are limitations on the complexity of shapes that can be produced and the need for specialized dies. It's often used for producing the bottle body itself, particularly the cylindrical shape.

The choice of manufacturing method will depend on the specific requirements of the water bottle design, including the desired material, complexity of shape, production volume, and budget constraints. Environmental impact should also be considered, with options like recycled plastics being increasingly important.