low volume alternative to injection molding

machined parts?

Look for a suitable off-the-shelf tube which can then have an endcap attached and other features milled into it.

I don't know how you're going to make it out of ABS unless you injection mold it or machine it from solid ABS stock, and the latter won't come close to your $3 cost unless the handle is very simple.

How about rigid polyurethane or epoxy? They both are strong and stable thermoset plastics. Depending on your labor situation, you probably could liquid-mold those in flexible silicone molds (commercial moldmaking silicone, not silicone caulk). You'd have to check on the compatibility of polyurethane with silicone -- something is ringing in my ears about it.

Anyway, this is a fairly slow way to make things but the tooling costs are dirt cheap. To make a dozen molds is cheap and easy; making a dozen or two parts per day is also fairly easy.

The resins are expensive but you'll beat your $3 price, unless this is a very big handle you're talking about.

Ed Huntress

The solution to your problem can be found at:

I would try GlobalSpec

Depending on the part, tolerances and material, what about rotational moulding? Another way may be vacuum forming in 2 halves and gluing or sonic welding together Geoff