I've been trying to think about how I would go about mass manufacturing a product I have in my mind. Basically, it consists of a handful of telescoping half-cylinders, about 12 inches in radius, about 18 inches long, and maybe 1/8" thick, probably made of LDPE. The issue is that each piece has a slightly smaller radius than the one it telescopes into, so injection molding is out of our budget because we would have to pay for 7 or 8 different relatively large molds.

Is there a process you might recommend for something like this? Everything I can think of would require 7 or 8 different molds (roto molding, compression forming, inj. molding, thermoforming, etc). I have a feeling the answer is no, but any ideas that allow me to not use 7 or 8 molds? 
You need to do an ROI on all candidate manufacturing processes. Consider extrusion manufacturing in your research.
what about extruding them differently, and then merging them with hot forming? but that would require 7- molds as well

<>Ideas for manufacturing a slightly variable part

 

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