# PURALUM — Prototype & Manufacturing Roadmap **Version:** 3.0 **Status:** Pre-prototype concept stage **Last updated:** 2026-06-18 --- ## Where we are now The product exists as: - A written spec (`docs/product-design-spec.md`) - AI-generated concept images (inconsistent — V3 image regeneration required) - A demo website There is no physical prototype yet. --- ## Phase 0 — Design lock (current) **Goal:** Agree on one physical design before spending on tooling or samples. - [x] Write canonical product spec - [x] Document prohibited design forms - [ ] Commission a 3D render or CAD file from product designer - [ ] Review render against spec — confirm dual-surface layout, cap system, refill mechanism - [ ] Approve master render as Reference Image 1 for all future image generation - [ ] Confirm product name: "Dual-Surface Crystal Applicator" (pending mechanism confirmation) **Cost estimate:** $300–800 for industrial design render/CAD **Timeline:** 1–2 weeks --- ## Phase 1 — 3D print prototype **Goal:** Hold the actual shape in your hands. Validate ergonomics, grip size, cap fit. Steps: - [ ] Convert approved CAD file to print-ready format (STL) - [ ] 3D print in rigid resin (SLA) — accurate surface finish - [ ] Fabricate dummy crystal inserts (cast resin, matching milky-white appearance) - [ ] Test: does it sit in hand correctly? Are both surfaces accessible? Do caps click on/off cleanly? - [ ] Photograph with real camera (this replaces AI-generated product images for phase 2 onwards) **Cost estimate:** $150–400 for SLA print + post-processing **Timeline:** 1–2 weeks after CAD complete --- ## Phase 2 — Crystal compression test **Goal:** Confirm potassium alum can be compressed or grown into the dual-surface shape. **Options for crystal sourcing:** | Method | Description | Notes | |---|---|---| | Ground + compressed | Raw alum ground, mixed with minimal binder, pressed into mould | Common for crystal deodorant sticks. Possible for custom shapes. | | Grown crystal | Alum crystal grown around a seed in solution to fill a mould | Slower, less predictable shape. Beautiful finish. | | Cut from raw block | Raw alum block shaped by CNC machining | Precise. More waste. Possible for prototyping. | **Open questions:** - [ ] Which method gives best surface finish for flat + convex dual face? - [ ] Can crystal withstand daily wet/dry cycling without cracking? - [ ] What is the expected weight per refill cartridge? - [ ] Durability under 30 cm drop test? - [ ] How does the crystal attach/lock into the housing at both ends? **Cost estimate:** $200–600 for test batches across methods **Timeline:** 3–6 weeks --- ## Phase 3 — Manufacturer RFQ **Goal:** Get quotes from real manufacturers for housing + refill cartridge. **Housing manufacturing:** - Material: Food-grade silicone over-moulded onto polypropylene core - Process: Injection moulding (silicone over-mould) - MOQ estimate: 500–1,000 units (typical for custom silicone) - Lead time: 8–14 weeks from tooling approval **Crystal refill cartridge:** - Likely a specialist alum product manufacturer - China, Taiwan, or specialist EU suppliers - Consider existing crystal deodorant stick manufacturers who can customise shape **Packaging:** - Kraft paper box + forest-green printed interior - FSC certified paperboard preferred - MOQ: 500–1,000 units typical **What to send manufacturers:** - CAD files for housing - Crystal spec (shape, weight, material) - Pantone colour references (forest green, ivory) - Logo file (vector SVG/AI) - Brand style guide --- ## Phase 4 — Beta units (10–30 units) **Goal:** Real product in real users' hands. Collect genuine feedback. - [ ] Assemble 10–30 units from prototype housing + crystal - [ ] Send to 10–30 testers across USA and Australia - [ ] Collect structured feedback: hygiene, odour control, skin feel, ergonomics, cap usability, crystal durability - [ ] Collect written consent to use feedback in marketing (labelled as "product tester feedback") - [ ] Photograph real product (replaces all AI-generated images) - [ ] Update claims based on actual test results - [ ] Update website with real tester quotes (never invented) --- ## Phase 5 — Pre-launch inventory **Goal:** 200–500 units ready to ship before any paid ads go live. - [ ] Place first production order (500 units recommended minimum) - [ ] Confirm fulfilment partner (3PL for USA, separate for AU, or start with one market) - [ ] Set up shipping rates, delivery estimates, and returns process - [ ] Update website with real shipping policy - [ ] Remove all placeholder shipping claims - [ ] Brief customer service process --- ## Unit economics checklist (before first ad spend) Calculate BEFORE running any paid ads: | Cost item | Status | |---|---| | Selling price | Placeholder $27.99 USD — needs COGS review | | Crystal refill COGS | Unknown — needs supplier quotes | | Housing COGS | Unknown — needs manufacturer quote | | Packaging cost per unit | Unknown | | Payment processing (Stripe/PayPal ~2.9% + $0.30) | Estimate $1.12 per order | | Pick and pack (3PL) | Estimate $2–4 per order | | Average outbound shipping (USA) | Estimate $4–8 per order | | Returns rate | Assume 5–8% for budget | | **Minimum viable selling price** | Calculate after all above known | > Do not begin paid ads until contribution margin per order is calculated and break-even CPA is known. See `docs/claims-policy.md` for approved claims at each stage. --- ## Key supplier categories to research - Silicone product manufacturers (custom housing) - Crystal deodorant manufacturers (alum refill) - Sustainable paper packaging suppliers - 3PL fulfilment (USA + Australia) - Product liability insurance (required before selling) - ACCC/FTC compliance review (before first ad) --- ## Timeline summary | Phase | Milestone | Estimated time from now | |---|---|---| | 0 | Design lock + 3D render | 1–2 weeks | | 1 | 3D print prototype | 3–4 weeks | | 2 | Crystal compression test | 6–10 weeks | | 3 | Manufacturer RFQ + tooling | 10–20 weeks | | 4 | Beta units + tester feedback | 22–28 weeks | | 5 | Pre-launch inventory | 30–40 weeks | | Launch | First paid ads | ~9–10 months from now |