Warrior Trail gave us a peak behind the curtain. This very cool series of photos shows their training plate production process. It’s kind of like the crayon factory episode of Mister Rogers’ Neighborhood but more tactical…
The production starts here where 100% recycled PVC, in powder form, goes into the hopper.
The PVC comes out of the extruder in a ribbon that is very hot. It is partially cooled with a water bath.
The PVC ribbon goes through a roller to compress it to the proper dimensions. It is still warm and flexible when it comes out of the roller.
It can take a while to reach a consistent quality from the roller. These rejected ribbons will be ground up and fed back into the hopper.
The ribbons are cut to length.
The corners are clipped and the bi-curve shape is applied.
The plates are cooled in a water bath before having their sharp edges removed and their iconic hole drilled.