HAUL 23 L cooler: rotomolded double wall, injected PU foam (concept)

Concept project: a 23 L hard cooler designed for rotational molding. The body and the lid are each one rotomolded LLDPE part: a closed 5 mm skin with a 35 mm gap that is filled with injected PU foam after molding. There are no seams to leak and nothing is screwed into the foam. Design for manufacturing: - Walls 35 mm apart. Rotomolding needs about 5x the wall between parallel skins for the powder to flow, so 35 mm against a 25 mm minimum. - Liner drafted 3 degrees, because the part shrinks onto the liner core. The outside walls shrink away from the mold and get 1.15 degrees. - Hinge knuckles, latch keepers, rope lugs and the drain tube are molded into the skin. - Freezer gasket sits in a groove in the lid. Rubber T-latches, a steel hinge pin, a screw drain plug and rubber feet. Checked in CAD: - 0.000 mm3 interference across 16 part pairs. One rope handle clash was found and fixed. - 22.7 L inside and 27.8 L of foam, measured from the CAD cavities. - Exact draft check: 99.3% of the body at 1 degree or more along the pull. Included: hero render, exploded view, section, GA drawing, annotated section and three colourways (Dune, Moss, Glacier).