We have been working on a flat pack bird box kit with the aim of making an attractive product with low tooling costs that is also cheaper to post.
With a product that is traditionally made in wood it was vital to create a more natural / organic surface finish to the plastic panels by creating an almost bark like texture. This made the CAD/CAM more interesting! – but it has produced a beautiful finish that can blend into more natural environments. A UV stabilizer is added into the material to prevent the Polypropylene from degrading. And the material used to make the box is 100% recycled post-consumer waste and is itself recyclable.
The whole product was made using three moulds, two of which are flat plate moulds which are much cheaper to make. The moulded panels are then assembled with finger nuts.
As the product will mainly sell through single online sales it was also important to keep the cost of postage as low as possible and so the panels were designed to be as slim as possible so that a kit can fit under postage dimensions.
So all the elements of the brief were met from design, environmental considerations, cheap tooling and efficient postage.
The kits are now for sale through our sister company Proops Brothers Ltd and can be purchased by clicking here.
