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Blow molded, Rotationally molded, or Injection molded? How to make a Good Duck

Blow molded, Rotationally molded, or Injection molded? How to make a Good Duck

Which came first, designing the mold or designing the rubber duck? In the case of The Good Duck the bigger question was which process, blow molding, rotational molding, or injection molding, will result in the best rubber duck ever?

injection molded novelty items

Following through on a crazy idea, Craig Wolfe premiered Betty Boop Duck in 1997, and his company, CelebriDucks was born. Originally invented in the USA, this American icon had long since been outsourced over seas. CelebriDucks returned the art of rubber duck manufacturing back to the United States.

From NBA players, to Mr T, and KISS’s Gene Simmons, CelebriDucks are collectible rubber ducks fashioned after some of the greatest icons of film, music, athletics, and history. CelebriDucks was voted the top fan give-away by ESPN in sports stadiums all over the country.

Not easily satisfied, inventor and CelebriDucks founder Craig Wolfe, had to take the product to a higher level. His most recent invention, The Good Duck, is known as the safest rubber duck on the planet.

As most parents know, the first thing babies do when they grasp an object is to put it in their mouth. The Good Duck is made of medical and food grade materials that are soft and safe for teething children. FDA approved, PVC, Phthalate, lead and BPA free, The Good Duck is 100% Made in the USA, and it floats!

With all great ideas comes research and development. Knowing he wanted a safe, soft, rubber duck that floated, Wolfe knew BPA free and PVC free was the way to go. Hence, his tour of blow molding and injection molding plants throughout the United States. As he bounced from factory to factory researching processes and materials he noted SPI Blow Molding in Coloma, Michigan was already using a soft material that could work. Safety and softness was key for the cute duck.

SPI Industries won the development of the Good Duck

Wolfe explained the determining factor for choosing SPI Industries and SPI Blow Molding was the expertise of the people compared to other plastic manufacturing facilities in the mid-west.  SPI had the experience with reach and development to support The Good Duck project.

Still, that’s only part of the story. The softness of the material, the product safety, and the desire for ducks of different color took much trial and error. Choosing the correct material, one that would remain very soft and hold design detail into molds is challenging. Fine tuning CAD designs, re-molding, sculpting, testing and refinement of molds was time consuming and expensive.

Should a Good Duck be blow molded, rotationally molded, or injection molded?

The Good Duck design was originally planned to be injection molded. Once Wolfe started working with SPI Industries, owned James Doster, advised him on a different direction. With injection molding the Good Duck would be in two pieces. The two pieces would need to be glued together. SPI engineers explained, “The plastic needed for the injection molding method would be too hard and would require welding.” Because a true rubber duck needs to float, it needed to be hollow. Blow molding it as one piece and sealing in the bottom was the solution.

The next challenge was determining wall thickness. The soft material they wanted to use with the characteristics that make the Good Duck safe and chewable doesn’t flow like normal resins. Getting the wall thickness exact took some time.

“SPI Companies do more than just manufacturer, they’re trail blazers. They’re making a difference in every way they can, creating jobs and producing innovative products with cutting edge technology.”

For the Good Duck to be completely safe, color needed to be molded right in the product. Adding color was a another challenge because colorant adds weight and effects the floating capability. Consistent balance was critical and very intricate. “Not easy technology, but SPI came up with a formula that is top of its grade with an age grading of 0 and up and thus completely safe for ALL ages!” reported Wolfe.

SPI also provided a great supplier for packaging services for The Good Duck. American gift boxes are usually very expensive and drive up price point. SPI staff helped to locate a gift box manufacturer right here in the United States, keeping cost in line and also ensuring The Good Duck is 100% Made in America.

Future plans are in place to expand The Good Duck line because it is so unique. Communities who hold annual duck races as fundraisers can now use American made ducks! The Good Duck may also be employed as a promotional piece with custom embossing or silk screening of logos.

Wolfe says. “What’s good for you and the planet is the right thing to do. The Good Duck should be done and we should be making it in America. We now have a niche as we’re the only ones making them here and The Good Duck cannot be duplicated anywhere. It’s a cute little duck!”

Wolfe insists on getting the best product out there and The Good Duck will come out of the gate very strong with the highest level of product safety. Watch for the blue, yellow, and pink Good Ducks on the shelves of your favorite stores as early as December, 2015. If you just can’t wait, you can pre-order Good Ducks on the website http://CelebriDucks..com, call 415-456-3452 or email info@CelebriDucks.com