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Evaluating a Plastic Pallet Design for mass production

Evaluating a Plastic Pallet Design for mass production

(OP)
Hello,

My colleagues and I are developing a new design for plastic shipping pallets, and need guidance on how to evaluate design options for mass production.

Quickly, we are prototyping options of these pallets that can have a full service life in the bottling industry, then be broken apart into roofing purlins. The decking of the pallet accepts standard water/soda bottle necks, so that builders merely screw on bottles to purlins -- no tools/nails/screws required. The result is a thatched roof of water bottles. (We have a pretty descriptive video here.)

Our technical problem is about assembling a few layers of our deking into a standard CP3 Block pallet, or 4-way-block pallet shape. Is this something that can be made at once with current injection modling technology? If we make layers seporately, are there ways to "fuse" these layers together?

Links, reading materials, and advice solicited.

More about our project:

WEB: sodabib.org
FACEBOOK: facebook.com/SodaBIBProject
KICKSTARTER: http://www.kickstarter.com/projects/jasonvannest/t...

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