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The majority of the public sees products after they have been completely designed, tested and manufactured. They rarely observe the creative process and countless iterations that were required to attain the end result. This is a fascinating process during which creative people must work together using their skills in engineering, art and science to create new products from an idea. It’s not unusual for hundreds of concepts to be created, evaluated and ultimately discarded. Only those ideas that comply with overall project objectives are selected and refined into the finished product. Often the most interesting concepts are discarded, never to reach the marketplace. This article will take you behind the scenes of a project our firm was commissioned to complete approximately one year ago. This case study will discuss the significance of process and material selection, and its affect on overall design. A discussion of rotational molding design possibilities will be explored and compared to alternative processes such as sheet metal, pressure forming and casting.