The Challenge

A fast-growing US e-commerce brand wanted to enter the STEM learning category quickly, with OEM tooling, reliable stock and zero customs friction — but had no local manufacturer and tight margins on entry-level pricing.

Our Approach

• We proposed a modular tooling plan that let three product lines share molds, cutting development cost by roughly a third.

• Every component was pre-tested in-house against CPSIA and ASTM F963 before shipment, so nothing waited on third-party labs.

• We staged production so the brand could launch the flagship line first and fill the rest of the range as sell-through grew.

The Result

Three certified product lines launched on schedule, cleared US customs without a single inspection hold, and reached a 2.1× reorder rate within two quarters.