Customization Process for Silicone Tap Lights

I. Requirement Confirmation (Initial Consultation)

1. Client-provided items: Reference images / sketches / IP character (Lulu the Capybara), dimensions, light color, battery type, brightness levels, product functions (tap-to-activate sensor).

2. Parameter confirmation: Silicone casing material (food-grade vs. standard), power supply method (rechargeable vs. button cell), surface finish (spray coating / screen printing / embossing), logo placement, color codes.

3. Commercial confirmation: Minimum Order Quantity (MOQ), target unit price, lead time, packaging requirements, certification needs (CE, FCC, etc., for cross-border sales).

II. Prototyping Stage

1. 2D Rendering: Create product appearance renderings based on the character design to confirm shape, proportions, and details.

2. 3D Modeling: Create a 3D model after rendering approval; provide 3D previews and verify internal structure (housing for the light board and battery).

3. Prototype Fabrication: Produce CNC or 3D-printed prototypes from 3D files; assemble circuits to create the initial "tap-light" sample.

4. Sample Approval: Client reviews appearance, tactile feel, lighting, and tap-activation function; provide feedback for modifications and fine-tune shape/circuitry until the final sample is approved.

✅ The approved sample serves as the standard for subsequent mass production.

III. Mold Development (Tooling)

1. After sample approval, manufacture the steel silicone mold (generic mold vs. custom mold; IP character designs typically use custom molds).

2. Mold Testing: Produce test silicone casings; inspect for shrinkage, flash, and parting lines; adjust/refine the mold.

3. Structural Integration: Assemble and test the silicone casing with internal PCBA, battery, and switch components; verify the stability of the tap-activation sensor.

IV. Mass Production

1. Material Preparation: Silicone color mixing; procurement of light boards, batteries, wiring, and packaging components.

2. Silicone Production: Vulcanization molding → trimming → surface treatment (spray coating, logo screen printing).

3. Electronic Assembly: PCB soldering, battery installation, and housing assembly to create the finished "tap-to-light" product.

4. Comprehensive Functional Testing: Each unit is tested for tap-sensor responsiveness, lighting performance, and battery life; defective units are rejected.

5. Visual Quality Inspection: Checking for dirt spots, cracks, color variations, or paint peeling on the silicone components and screen printing.

V. Packaging and Shipment

1. Packaging: White box, color box, or blister packaging; box printing customized to client specifications.

2. Pre-shipment Inspection (Sampling): Verification of quantity, product appearance, functionality, and packaging.

3. Boxing and logistics arrangement; simultaneous provision of shipping documentation and quality inspection reports.

VI. After-sales Service

Warranty terms for bulk orders; mold ownership agreements (Private mold: owned by the client; Public mold: factory retains sales rights).