Now Accepting Pre-Orders ! |
After a Tik-Tok hit in January, we sold out in a week! So we upgraded to a new factory. And I am delighted with their work! So we're now accepting pre-orders. We expect to ship by March 31 on a first-come, first-served basis. But it might sell out again before then. So pre-order now. It's the surest way to secure your SPACE®. Tell your friends, too! Who wants to put up with a psycho shower curtain ? May the SPACE® be with you ! Patrick the Inventor |
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We shipped 55% of all pre-orders this week. And we have *finally* received enough inventory to ship to the rest of you next week. This has taken longer than it should have, so I’m grateful for your patience. Enjoy this video update for more details. If you haven't pre-ordered yet, now's the time. May the SPACE® be with you! Patrick the Inventor |
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The folding windows arrived and they look great! They were the last component we were waiting for.
We will start shipping next Monday on a first come / first served basis. Some pre-order customers have been waiting since September! They will ship first. I'm sorry we missed the October delivery target.
Enjoy this video update for more details. If you haven't pre-ordered yet, now's the time.
May the SPACE® be with you!
Patrick the Inventor |
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Happy news! Latest production run from our new contract manufacturer in California is almost complete. See this video update for more details. If you haven't pre-ordered yet, now's the time.
May the SPACE® be with you!
Patrick the Inventor
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Did you see it?
Yes, we added 2 splash-guards with suction cups! They keep the window fully extended wall-to-wall, up to 60 inches.
Keep water in and cold air out. This is your daily sanctuary.
Secondly, we added more decorative designs.
These are optional extras. You can add them outside while the SPACE® Liner is inside.
Lastly, some of you have asked if custom sizes will be available? The answer is yes!
Everybody's bathroom is unique, and one-size does not always fit all. So you can expect Stall (narrow) & Stretch (extra-wide) and Tall & Short (length) options soon.
Meanwhile, our current item fits most standard tub showers: 60"Wall-to-Wall x 80"Extra Long.
Something to smile about every day.
Happy Bathing !
~ Patrick the Inventor
Times are strange and people are understandably stressed. My job is to give you something to smile about: more shower space.
Happy bathing!
~ Patrick the Inventor
]]>As for our project, we were finally able to fine tune our machines. Three weeks ago, I sent samples for in-home testing by real people. I waited for their verdict ... and they love it. Our new product looks and works great. Here it is ...
]]>(see full transcript below)
Well, here we are … success! Firstly, let me say that I fully recovered from COVID. And thank you to all who wrote in with expressions of concern and support. Very appreciated. I’m fine. And New York City will be fine.
As for our project, we were finally able to fine tune our machines. Three weeks ago, I sent samples for in-home testing by real people. I waited for their verdict ... and they love it. Our new product looks and works great. Here it is:
So, my dear backers, it’s been over 2 years. What a journey! In gratitude for your early support, I will ship you a FREE UPGRADE. Now a lot has happened since I made that promise... so I’m sure you’ll understand that I can’t ship to all 326 backers all at once, but we can make this work. Please start by replying directly to my email to confirm one last time that I have your correct mailing address. With all the recent upheavals, many of you may have moved.
So here’s how shipping will get done:
First in line is everyone who made a voluntary donation to cover the shipping cost of a second shipment. If you want to join Group 1, it’s not too late, just click this link. Now I know times are tough, so if you can’t afford to donate $10, you can still join Group 1 with an equally valuable contribution: click any of the social media links here to tell your friends that you supported our project.
This is a simple non-cash action that has great value because it could bring in new customers and reduces marketing costs for my small business. When you click any link, my social media accounts will see your post, then you’re in Group 1.
If you can’t donate $10 and you don’t want to click on the social media links, then you are in Group 2. I will honor my pledge to ship your FREE REPLACEMENT, but only after Group 1 is processed and after my small business has enough cash flow to pay for your shipping cost. It could take a few more weeks. But it will get done.
In closing, this success wasn’t just the work of a solo inventor. It’s thanks to you, Kickstarter backers, who believed in me and the concept of a self-expanding shower liner, before it was even a real product. I also want to take a moment to thank all my teammates who contributed time, talent and early startup capital: Anne, Mickey, Louis, Jonathan, Lucy, Nick, Kristin, Richard, Louise, Duks, and Mom. I could not have done this without you. Thank you.
And last but not least, thanks to all the amazing engineers, contract manufacturers and essential workers who report to work every day. We owe them all the more, given our challenging times. I won’t comment on current events. That’s not my job. My job is to give you something to smile about: more shower space.
Happy Bathing to you all.
]]>
Hi everyone. I hope you're all keeping safe and sane.
Sorry for disappearing for the past 3 weeks, but I caught Covid-19. My case was mild, but that’s like saying I was mildly hit by a truck. Really, my friends, this disease is awful. Don’t catch it. I was never in any danger, because as bad as my symptoms were, friends kept checking in on me and my symptoms didn’t worsen. I just stayed here in my room in New York, in and out of feverish sleep. I'm much better now. I went for a walk in the park today … with a mask, of course … and it was wonderful to get out and take so many deep breaths. I’m feeling very lucky and grateful.
So back to work. Last we spoke, I told you that March 31 was the manufacturing deadline for my suppliers. And they all delivered on time. The boxes, the bags, the fabric shower liners, all done. And I’m happy to say that here are the actual parts: hoop and panel. These are stain-resistant, double-polish plastic, custom made in the USA. Water beads right off, so they dry super-fast. Notice also how they’re a beautiful diamond white. The original was too translucent. This is better because it lets light in while ensuring privacy.
We assembled one complete item 10 days ago. And it was close, but didn't pass final inspection. See these stressmarks in the top corners? They’re not supposed to be there. The product still works fine, but it doesn’t look right. I can’t release this. Our machine needed a new part, which we ordered right away, in the middle of a global pandemic, not knowing when it would arrive. Well, it arrived today. So our machinist is making the change on Monday. Let’s give him a few days for fine tuning, then we should be ready to go. The machine is very quick. I’ve been calling him almost every day. He hates me by now. And this factory also makes plastic medical equipment and food packaging, so we have to accept whatever place they give us in the production line. These are good people doing a great job in stressful circumstances.
So there you have it. I emerged healthy from Covid confinement to find mass production almost finished and hundreds of people like you are on the waiting list to buy my product. Things could be much worse. Like I said, I’m feeling very lucky and grateful indeed.
Happy Labor Day!
]]>Frankly, I was expecting a shutdown. But the American factories that are making our product also manufacture highly regulated items like food packaging and medical equipment. Because of that, they are classified as “essential“ to the national supply chain. This includes our distribution facility, where our item will be assembled and shipped.
]]>
Hi everyone. I hope you're all keeping safe.
Many of you have asked if we’re still on schedule given the current crisis. The answer is yes, I expect production to be finished around April 7. That’s 1-week later than I wanted, but it has nothing to do with the virus, believe it or not! It was just a technical delay with one of the new pieces of equipment. This happens when you’re using new machinery for the very first time.
Frankly, I was expecting a shutdown. But the American factories that are making our product also manufacture highly regulated items like food packaging and medical equipment. Because of that, they are classified as “essential“ to the national supply chain. This includes our distribution facility, where our item will be assembled and shipped.
All our suppliers follow strict CDC protocols. They do a full disinfecting wipe down every hour. Workers are in gloves and masks. It slows things down a bit, but it’s worth it. There are no cases of infection that I am aware of, and I speak to them almost every day.
I would go work on an assembly line myself if I could, but I’m in lockdown here in New York City. But I’m fine. I work from home and we use video conferencing to review all engineering and logistics.
So, the machine-washable Shower SPACE® will be on Amazon some time later this week. And I’m extending the pre-order special with free shipping until April 7 on www.MoreShowerSpace.com.
You can feel good about what we’re doing together: keeping people working while keeping everybody safe.
Bye for now!
~ Patrick the Inventor
PS: Here's our latest schedule
]]>
Our US manufacturing partners are operating with a high degree of care and at optimal capacity. I want to do my part as a small business to cope with this pandemic conscientiously, while maintaining full business continuity.
]]>Your shipments are being prepared. We are fortunate to be well-positioned. All my vendors and teammates work in a safe environment -- or remotely, like I do.
Our US manufacturing partners are operating with a high degree of care and at optimal capacity. I want to do my part as a small business to cope with this pandemic conscientiously, while maintaining full business continuity.
For the sake of radical transparency, our latest production schedule is below
Stay safe and Sane.
~ Patrick the Inventor
]]>
Here's to the product feature of the day!
Bye for now!
~ Patrick the Inventor
]]>Ok, my friends, we did it. We solved the production issue. We’ll be back in stock in 21 days. Many components are already finished and the rest is on schedule. Made in the USA, baby!
So I just reopened my online store. Go ahead, pre-order now. You get guaranteed first delivery and free shipping, a $10 value.
In my last video, I was telling you how we were stuck because I couldn't get the big expensive industrial machine to cut and fold the patented panels. The breakthrough came when one of my advisors found an alternative. It will cost me a little more per unit, but it's a common machine used by lots of domestic manufacturers. It's fast enough and the tooling cost was low enough. So I put it on my corporate credit card last week. Now that we have the right partner with the right machine we will be back in stock in about 21 days.
I'll be doing short daily countdown video updates from now on. You’ll see the real samples as I get them next week. I will also be introducing you to my team. There are lots of good people I want to thank.
Last thing: I said I might do a funding round. Well, I'm still open to it. You can message me if you're interested. But frankly, because my small business doesn’t need the big machine any more, we don't really need money. We can grow just fine with pre-orders and sales revenues.
But here's what I do need. I need your help for people to discover my product. Google and Facebook advertising have become really very expensive. Instead, I’d like to ask each of you to post MoreShowerSpace.com on your social media. It’s a super-valuable non-cash way for you to help our small business. Just say, hey, I know this guy and his new product looks cool or something like that.
So, option 1, you can pre-order now. And if you don’t need a new shower curtain, I get it … then option 2 is to post about MoreShowerSpace.com on your social media. Especially you, my dear Kickstarter backers. I’m still committed to sending you a free upgrade. This new version is simply amazing. You’re really going to love it! But I can't do this alone. I'm counting on you to post MoreShowerSpace.com on your social media, so we can all enjoy more shower space!
So that's all for today. I know it's a crazy time. So stay safe. Stay clean. Stay calm. And stay on schedule. That's what I'll be doing.
Bye for now!
~ Patrick the Inventor
]]>Here’s a synopsis ... our Kickstarter campaign proved:
The product now passes 12 out of 12 testing requirements. But in order for me to reopen the online store, guarantee pre-order delivery and ship free upgrades to hundreds of early backers like you, then I need the capability to reliably make thousands of units every month. For that, we need to be able to mass-manufacture 7 components at optimal cost, quality and speed:
They are all ready … except #5. It's not a problem with the material. It's that after weeks of applications and disclosures, we were repeatedly led-on -- then ultimately denied -- equipment financing for the "pleating" machine. So this month, we switched to a different creasing method. It's a bit slower, but it involves a more common machine available at many US contract manufacturers. So next week, I’ll shoot another video with these announcements:
Any questions? Simply email me or call (888) 856-7622.
May the SPACE® be with you!
Patrick Raymond, Inventor
]]>This improved version is simply amazing: no buckling, no vinyl smell, no snaps. To all my early customers, thank you for your patience and support during this seemingly endless phase 2 of product development.
We should ship around January 31, 2020. I have emailed you all individually asking if I need to update the mailing address I have on file for you. Meanwhile, if you care to donate $10 for second shipping costs, I would certainly appreciate it. But this is purely voluntary. I'll ship your free replacement regardless.
Alternatively, you can help my small business and earn cash for yourself: invite your friends to pre-order, they get FREE SHIPPING, you get $5 per order. But hurry! They must order before ship-day, and while quantities last.
As always, I answer all inquiries personally. Message me or call (888) 856-7622.
May the SPACE® be with you!
Patrick the Inventor
]]>I can't share photos, but here's an image for you to consider: over dinner, the master contractor said he never imagined he'd end up in the shower curtain business. Neither did I, was my reply. We laughed and raised our glasses!
Now we'll need to buy some custom machinery for mass production. Expected delivery is 6 weeks. Although the equipment can run at impressive speeds -- and I was hoping to ship your units before Christmas -- I think it's safer to wait until everything is in the shop and fully tested before I make any bold predictions on shipping dates. But I am feeling more confident than I ever have. Our engineering specifications were reviewed, refined and validated by some of the most impressive manufacturing professionals I've ever met.
Stay tuned for more frequent updates from now on. I will soon re-open my online store to pre-orders.
Sincerely,
Patrick the Inventor
A bit of background ...
In update #16, I described my visit in May to factories overseas. But as I wrote in update #17 last month, that collaboration was ultimately not a success because the samples did not pass all 12 testing criteria. In the end, I lost many months and thousands of dollars. And you are all still waiting, I know.
I thought all we needed was a simple material change. But the problems ran deeper. I never shared with you how I was feeling uneasy with the 3 E's of the situation: Ethics, Economics and Ecology. On the Ethical front, I was rather shocked by working conditions overseas. But I dismissed my misgivings as naive. I was a Westerner, a city-dwelling snowflake, unaccustomed to factory floors in Asia. That's all.
Then over the summer, the Economic picture began to darken. Not only did double-digit trade-war tariffs inject needlessly stressful uncertainty to our financial plans, but the manufacturing numbers themselves didn't add up! Our product was being made in an all-manual way: multiple workers lined up to perform mind-numbingly repetitive tasks, 6 days a week, 9 hours a day, paid $200/month. This struck me as not only ghastly, but also supremely wasteful. Our panels are just a repeat pattern. Why not complete repetitive steps with well-designed, high-capacity machines instead of a line of unskilled workers? Some products (like fashion and textiles) are unavoidably labor-intensive, because milling and sewing are still inescapably manual. Machines can't do those tasks well (yet). But an all-manual assembly line is nonsense for our product. I was told by my broker not to worry about it, because labor is "so cheap" over there. But I disagreed. It was just bad economics to employ army of unskilled workers: too expensive, too slow and too inaccurate.
And finally, from an Ecological standpoint, well... I felt uneasy, gazing from the 22nd floor of my "luxury" hotel, factories sprawling into the horizon, all powered by coal-generated electricity, belching what looked like raw exhaust. It was Dickensian. Now don't get me wrong, I'm no ideologue. I am an inventor and lover of free-markets. And I had a job to do (for you). But too many things seemed off. I had a choice to make.
Because the material was being changed last month, production was halted anyway. So I read up on polymers. Turns out they are a global commodity, traded on global markets. So buying raw resin to make plastic is the same price here as overseas. Next is the high-capacity machinery. Some of these behemoths run 3,000 feet per minute. It's incredible. But could it work for our product? The creases in our panels are the key. And our material is unusually thick for these machines. We couldn't run it that fast. So I read up some more, learned about things like "molecular orientation" in plastics. Then I contacted American equipment manufacturers. They could tell I was an amateur. Some weren't very receptive. But some were. One in particular (the biggest, surprisingly) agreed to run tests on their machines with our material. Success! The folds are perfect "living hinges" that don't break, and the panels don't buckle.
Last step was to find a domestic factory that could make plastic sheets ethically, ecologically and economically, with skilled American workers paid fair wages to run the high-capacity machine. I'm happy to say our partner factory has been found. The high-capacity machine will take 6 weeks to make, and a week or two to test. Then, hundreds of units can be made in a single day. It's the speed, precision and low worker-count that brings the unit cost down to acceptable levels.
So in the end, 15% of the product will be made in China (textile liner & curtain) while 85% of the product and value will be made in the USA (panels, hoops, box and final assembly).
More news in November ...
]]>Because here’s the good news: this new version is amazing in every other aspect! We suffered a material failure on only one part, not a design failure. New suppliers have already submitted bids. We’ll quickly test their material and creasing/sealing methods, and jump straight into production (which is surprisingly quick). I could give you an estimated timeline, but it would only reflect our collective impatience! All I can say is it’s likely a matter of weeks, not months.
As soon as we pass all 12 tests, I will open the store to pre-orders. Meanwhile, all Kickstarter backers and version 1 customers can still expect your free replacement.
]]>In 2018, I spent $80,000 in time, materials and equipment to fulfill $15,000 in orders. If I had to do it all over again, I would ... because you all supported my project! And I gained a lot of valuable learning.
]]>In 2018, I spent $80,000 in time, materials and equipment to fulfill $15,000 in orders. If I had to do it all over again, I would ... because you all supported my project! And I gained a lot of valuable learning. From a design perspective, we now know what works -- and what doesn't -- to manufacture my product. I am still 100% self-financed, with the help of a few dedicated equity partners and specialists who provide invaluable advice and support.
Alas, our original manufacturing partners will not be able to make more units. They could not scale up. Costs were prohibitive for all involved. Nobody is to blame. So I spent the past few months seeking a larger manufacturing partner. After a long search and many technical discussions, I'm happy to say that we found a suitable facility for mass production. I placed an opening order last week and am going overseas at the end of May to personally inspect the production line.
I have received and replied to all your public comments and private messages about the product. It doesn't matter if your comments are positive or negative. As the inventor, it is incredibly valuable for me to get real-world feedback from early backers like you. I think we can all agree with what requires improvement:
I'm happy to announce that I have found a way to resolve all these points. I will be testing and posting photo updates about Version 2.0 next month. Because of your patience and support, you all qualify for a Free Upgrade. I can't promise exactly when you will get your new units, but I can promise that you will. I am working hard to find a way to finance this project. Stay tuned for more details :-)
Happy Bathing!
~ Patrick the Inventor
]]>I can only say with certainty what I have observed personally: most (though not all) windows have been received, pre-assembled with a liner and folded into boxes. I'd like to ship to everybody in one go (it's fair to all, and faster anyway).
Believe me, nobody wants this done more than me: we are sold out, and I have been working on this (unpaid, with no other job) since October 2017. I am eager to replenish and scale up operations with some larger (and faster) partners.
]]>The trucking company delivered our pleated windows a full week late. No excuse or explanation given. Welcome to my world :-(
But hey... they made it. And they're in fine condition. Our manufacturing partner did a great job. Please bear in mind that even while using The Machine, every complete window had to be painstakingly hand-cut, hand-creased and hand-sealed. To make one, they had to perform 23 "shots". That's been very slow, and expensive, but it's done!
And as promised, you will receive your pleated window pre-assembled with the snap-on liner. We need time to do that at our local assembly facility. Then we fold, wrap, box and ship to you. Expect your notification next Wednesday.
Tell your friends ... less than 6 days to pre-order at pre-retail price.
Happy Bathing!
~ Patrick the Inventor
We are scheduled to pick up the hooped-windows this Wednesday. Once they arrive at our local assembly facility, pre-snap a shower liner on each window, fold, wrap, box and ship to you. Expect your final shipping notification next week.
Tell your friends ... time is running out to pre-order at pre-retail price.
Happy Bathing!
~ Patrick the Inventor
]]>Alas, one bad week will cost a full month, because our job is not the only one in the shop. I’m not about to berate our master craftsman for the delay, especially since I’ve seen how unforgiving it is to labor in 105 degree heat. I’m also deeply grateful he took on our job in the first place. Nobody else would. Yet we remain a tiny client to his shop. So we got bumped.
But what I did ask from this key vendor — and we now have — is a legally binding contract to finish by a specific date: September 28. I waited until I had the document in hand before writing this update to you all.
This delay doesn’t diminish the quality of the product you'll receive. Quite the contrary. As you saw for our latest photo session, the product is just AMAZING!
But the delay does hurt me. I am running out of funds. Since January, I've worked unpaid and unable to take other jobs. So this summer, I scaled down, kept an emergency reserve fund for food, rent and essentials (for me), plus all anticipated shipping costs (for you). I have spent everything we raised together, plus all my savings, plus any debt I qualify for … and put it in tooling and inventory. In other words, I'm "all in" Curvi curtains. More than ever, I need your support.
The good news is that once production is finished, I'll have 750 units. You all preordered 375. But I need to sell them all. Right now! I can't afford an advertising budget. I must rely on referrals to attract new customers. You can help by convincing just ONE FRIEND to also pre-order from this page. Or, if you prefer, here are some easy-sharing links:
I'm happy to offer your friends a pre-order special of $5 off expected retail price. And I'm sure they're going to LOVE the extra shower space :-)
Happy Bathing!
~ Patrick the Inventor
]]>
We finally got the Machine to align, cut and seal the perfect vinyl into a perfectly pleated window.
]]>So here we are. Delayed again. It’s the same part holding everything up. The Machine that makes our pleated window requires more fine tuning. It’s not cutting well enough, creasing deeply enough or sealing with enough accuracy 100% of the time. I just can’t release a product with even 1% of errors in it. Shallow creases + Rough cuts = Bad folds = Bad seals = Bad breakage = Bad leaks!
Now I’m assured by the Lords of the Machine that this sort of mechanical problem is a) typical for new manufacturing equipment and b) only requires another week for final tests and tweaks. The closest analogy I can think of is that of a desktop printer -- that keeps jamming -- but once the cartridge and paper are set right, the sheets print out quickly and correctly.
So although I am deeply disappointed -- and I am sure you are also -- there is no reason to feel uncertain. We will ship. I just can’t say exactly when. Because now, even though the Machine is likely to be working 100% very soon, other key partners and workers in our supply chain (for packaging and delivery) have started to go on vacation. In truth, they’re all contractors, so they don’t technically owe me prior notice. And everybody is entitled to vacation.
Now I understand why they say that disruptions in supply chains can “ripple” long after the original bottleneck has been solved. So if you ask me when you can expect delivery ... I've learned my lesson ... and will only answer "before Labor Day, we hope". I wish I had better news. This has been a long summer.
Sincerely,
~ Patrick the Inventor
PS: Oh, if you ordered a decorative curtain, the selection email still hasn't gone out. I have withheld it until production of the main parts (window & liner) is complete. But I have found a lovely collection of curtains that we can easily customize to fit on the window. You're going to love it! Please allow me more time to program the web pages with new images.
]]>At long last, we created the perfect material for Curvi™ pleated windows. It has the ideal balance of physical attributes -- like weight and “Goldilocks” flexibility -- and it performs well in the Machine for creasing, folding and sealing. Furthermore, it is an eco-friendly blend, in full compliance with the toughest environmental standards in the industry: California's Proposition 65. That means that it has none of the potentially harmful chemicals that cheaper shower curtains typically have. Best of all, as you can see from the photo, light will get in, but frosting ensures privacy. The matte translucent finish gives it a premium silky-linen look that will make your Curvi™ pleated window look beautiful from outside.
Frankly, I never expected this one component to be so challenging. The effort took many weeks and involved many experts in material science. But thanks to our polymer engineering partners in New Jersey … we did it!
On Monday July 16, we start folding and sealing the sheets into your Curvi™ pleated windows. We expect that to take a week, so let’s say two, to be safe. That brings us to July 30, when we will pick, pack and ship to you! If you ordered an outer curtain, expect a separate email from me tomorrow to pick your design. We ship to everyone at the same time.
Happy Bathing!
]]>Bad news: we won’t ship until mid-July.
Good news: production started, and is almost finished, so we are set to ship mid-July.
The delay is only due to one component, albeit an important one: the pleated window. It continues to be a challenge. My original handmade prototype was made with vinyl from a hardware store. I cut and taped it together. For mass production, you might recall from my previous update how I paid for a custom cut/crease/sealing radio-frequency tool -- the Machine! You might also recall that I stated that “the perfect vinyl” had been found. Indeed, I had been shown a suitable sample by a local sourcing agent, and was assured it would be available for mass production. So we ran tests with another type of vinyl to evaluate the cut/crease/seal operation of the Machine. I must express my deepest gratitude to the Lords of the Machine, who have put in countless hours and effort. I’m happy to say that it is performing very well.
But then, to my dismay, “the perfect vinyl” was proving elusive. Although I can’t know for sure, I suspect the sourcing agent might have been hoping that I would accept another type of vinyl … one that he just happened to have on his shop floor. Not only was it of lesser quality, it simply did not perform acceptably for our application. Then when I’d ask for vinyl closer to the “perfect” sample I had been shown, he kept assuring me that his suppliers (whom he refused to disclose) would have it “soon”. They never did. I effectively spent the past 6 weeks in a cat & mouse game, testing different (imperfect) vinyl options and waiting for a definitive answer on whether or not the right vinyl would arrive per my purchase order. Some weeks would go by without an update at all. This baffling “wait for the vinyl” game was very frustrating, and not only do I apologize for the delay, I share your frustration of feeling kept in the dark.
Sensing something was amiss, one Lord of the Machine referred me to his direct source for vinyl two weeks ago. They are an 100% American company based in New Jersey who manufacture tons of sheet polymers and coated fabrics in compliance with the highest quality and environmental standards. They sent a chemical engineer (with his apprentice) who took the time to listen to our requirements. Remember, our opening order is very small, and I was amazed and grateful they even showed up. They informed me that the combination of properties we wanted simply did not exist off-the-shelf or pre-made rolls of vinyl. It would appear that the previous sourcing agent was not accurately representing key aspects of how vinyl is actually mixed and made. Turns out that most industrial vinyl is made on-demand in a full “mill run” of a few thousand yards at a time. It’s not lying around somewhere, gathering dust, waiting to be ordered. So much for the vinyl “broker”.
But now, at long last, with the help of a reliable, direct source, we have the correct formulation for the perfect vinyl. I can’t divulge our trade secrets, but I can tell you that it is a very unique blend according to our very unique requirements. For example, just one aspect (finish) can’t be too polished, otherwise it “sticks” and also worker fingerprints and soap scum will stick to the window. Another aspect (clarity) is very unique in that it is not desirable to have it be 100% see-thru: it needs to be clear enough to let light in, but slightly frosted to maintain a comfortable level of privacy. We discovered 4 other properties that are in fact critical for our window to deliver a better showering experience for you.
The mill run will take 3 weeks, and the cut/crease/seal/fold operation will take at least another week. I approved this delay because I can only release the product in good conscience when it passes all tests and can deliver 100% satisfaction to you.
Everything else is just peachy. All the previously identified production issues have been solved. I purchased all the required materials and struck a manufacturing deal with Carnation Home Fashions, a major shower curtain importer and manufacturer based in Newburgh, NY. Therefore ...
We just need to wait for the pleated windows.
Oh, by the way … so far I have spent well over the $14k net proceeds from Kickstarter. This is typical for founders who absorb one-time tooling and equipment costs. But I am now personally financing this first production run. Since I am still accepting pre-orders on my website www.Curvi.co, and since the minimum order quantity for my production exceeds the number of Kickstarter backers, it would really help if you could encourage your friends to make a purchase. We will have extra units for them ready for delivery in mid-July :-)
Happy Bathing!
As many of you know, a crowdfunding project does not have specific deadlines -- only estimates -- because the item has never been made before. So first, I've had to seek US suppliers who can make this "custom" item for us. That's been harder than expected because our opening order is so small (560 units), so it's like asking a caterer to do a 5-person wedding! Then once I find suitable suppliers, it is generally impossible for them to predict accurately when all the different components will be ready. And I would rather not heap undue pressure on them.
But I’m happy to say that we've made a lot of progress, and you'll likely get your Curvi in late May / early June. I can’t say exactly what day. I hope this is acceptable to you. Please know that I am doing my utmost to deliver. Below is a recap of all the milestones we hit and challenges we are having … starting chronologically …
On March 14, I received $14k net proceeds from Kickstarter. I got right to work on finalizing the design, sourcing and production details.
Tooling:
Electronic Die Corporation in Canarsie, Brooklyn, has completed the two RF dies (one for cutting & creasing panels, the other for sealing then panels) and National Steel Rule & Die in the Bronx has finished the “clicker” die for hoop cuts. Final cost: $5,300. This went very quickly, barely 2 weeks.
Production
ET Manufacturing in Garfield, NJ, will source vinyl and oversee Adam’s Productions (in the same building) to run the “oversized” dies. We will perform actual cut/crease/seal tests on Thursday, May 3. If successful, the first 600 units will then only take 10 business days to make :-)
Meanwhile, the prefect vinyl has been found: ideal clarity, thickness, non-stick texture and “hand” (not too soft, no too rigid). It also has many health & eco-friendly advantages. This search took much longer than anticipated. I did not have access to catalogs with industrial samples. There are thousands of them, and they are only given to large manufacturers. John at ET Manufacturing (pictured) was instrumental in moving this process forward. Thanks, John!
Snaps in Header:
The liner (and optional curtain) must attach to the window. So I developed a simple attachment method: instead of standard 12-grommet holes, we’d have 7 snap-pairs. This was prototyped and successfully tested. I thought this would be a simple operation, yet I’m still seeking a supplier who can do this affordably! This is a baffling production bottleneck that I must solve soon. There are two options:
Liners:
They must be a light, water-repellent, machine-washable textile (not yucky plastic). Seemingly a simple request, they still must be “custom-made”. This has also taken longer than expected to source. Why? Because our spec is 100% unique: we require a custom size (70”W x 60”L with ½” hem on all 4 sides). Here also, I found two possible options:
Outer Decorative Curtains
Purchased by 120 crowdfunding customers (60 semi and 60 full-length) they must also be 100% custom-made. I will begin by offering a limited choice of simple colors/patterns. For those of you who picked this option, watch for a separate email from me in mid-May.
Custom Cut & Sew
This service will be required for both curtains and liners (to attach the snaps in the header). Unfortunately, few shops will consider our job (some won't even return my calls) because our opening order is so small. On April 27, I was allowed to visit Dynotex in Brooklyn, NY. I am hoping they will agree to provide a reasonable quote to do this job. They also offer assembly, packing and shipping service, which would be a good way to consolidate the work. If they are too pricey, the search must continue … :-(
Shipper Box
Success. Sample arrived in good condition from Modern Arts in Albany, NY. Artwork will include logo outside, brand message and illustration on the inside, plus a thank you card. Total unit cost expected to be affordable.
Assembly & Shipping
Likely to be at the Cut & Sew facility (TBD). We’d consolidate the windows, curtains/liners and boxes at one location, where they’d then get assembled, folded, packed, labeled and shipped. All your customer order information is safely stored, and I have a label-printing solution and shipping/tracking will be via USPS.
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