A boxing gym Company was searching for a factory capable of providing sponge cutting and molding services for their new boxing training set. This set included a sponge pillar over 2 meters long, surrounded by two human-shaped sponge products, requiring specialized polyurethane foam molds and sponge cutting techniques.
After searching for multiple Chinese factories, the client finally found us through our product links. Although we originally specialized in plastic product manufacturing and mold development, we decided to take on this challenge after thoroughly understanding the client's specific needs. Despite clearly informing the client that this wasn't our area of expertise, they still chose to collaborate with us, as no other factory had truly delved into their requirements, nor were they willing to invest much effort and time into an uncertain project. This was also a true reflection of many Chinese factories and salespersons. After in-depth analysis of the client's needs, and relying on our expertise in mold development, product design, and detailed communication, we accepted the order.
To provide a one-stop solution for the client, we carefully examined all the details of their requirements, created a communication issues list, and conducted in-depth analysis, particularly regarding product density, weight, transportation methods, and product assembly. Following a lengthy discussion with the client to obtain answers to all questions, we began production.
Although polyurethane foam molds don't require high precision in size, they are widely used in sporting goods and automotive accessories, with applications in sponges, cushions, and filling products. We first used CNC cutting technology to create a 3D model shape from ordinary foam plates, then placed the sponge-cut products into a sand mold, utilizing the softness and moldability of sand to create a preliminary model. After removing the sponge products, we poured molten aluminum alloy into the mold to obtain a preliminary sand-cast aluminum mold. The sand-cast aluminum mold still required CNC processing for size and surface roughness to meet the client's smoothness requirements.
Once processed, the sand-cast aluminum mold was placed on the foaming machine to produce the foam products. The foam products looked beautiful when first produced, with a soft and delicate white color resembling skin. However, they would yellow over time.
The client was very pleased with the first samples and placed an order for 1,000 sets of products after confirming the prototypes. Due to the large size of the products, 1,000 sets filled an entire container.
Just when we thought the project was complete, the client contacted us again. They complained about another supplier's issues with packaging fabrication, stating that the Chinese supplier had taken nearly two months and still couldn't provide a fully satisfactory prototype. Additionally, the factory was unwilling to cooperate due to the small order quantity, leading to uncertainties in subsequent production and delivery times. With the product launch date approaching, the client was very anxious and hoped we could help find a solution.
They needed an additional layer of waterproof nylon bags around the sponge products, so that boxers could directly punch the outer part of the bags during training. Since the product shape was an弧形 "8" and the client hadn't fully finalized their product design, only having some basic requirements, we used 3D software for simulation and 3D printing for verification. After confirming that we could meet all the client's requirements, we accepted this additional order outside our main product line, as we wanted the client's project to be successfully completed as soon as possible and for their investment to generate revenue.
Although this wasn't our main business and we didn't have a mature supply chain, our team eventually chose to collaborate with a nearby luggage factory after communicating with multiple unfamiliar suppliers. The main reason was proximity, allowing us to communicate instantly and face-to-face on specific details. Next, we had video conferences with the client and various meetings and discussions with the supplier. Within less than a month, we completed sampling and delivery. The client was surprised and pleased when they received the samples, as we were faster than their previous supplier in delivery and truly met 100% of their requirements in many details.
Among many complex projects, this one wasn't the most challenging we've experienced. However, in this project, our team truly listened to the client's needs, did our utmost to achieve the goals, and provided genuine one-stop service with all our hearts
Your message must be between 20-3,000 characters!
