Part 1 – Project Overview
Tempo de espera
In December, Shieldon’s collaboration with its French partner reached a pivotal stage. After months of discussions and adjustments, both parties reconciled the project’s ambitious design with the practicalities of modern manufacturing.
Shieldon’s team focused on optimizing structural integrity and proposed crucial changes to ensure the knife would be both innovative and viable for production.
Despite initial challenges, such as aligning the blade with the handle and integrating additional features like a corkscrew, both sides worked diligently to find solutions.
The goal was to preserve the knife’s unique aesthetics while ensuring its suitability for mass production. Shieldon delivered a design that met functional and aesthetic expectations by addressing issues like material compatibility and ergonomic efficiency.
Como surgiu o projeto
As the project transitioned into the prototyping phase, both parties remained optimistic. Shieldon assured its partner that the design would continue to be refined to create a product that exceeded market standards.
The collaboration successfully integrated creative vision with practical expertise, ensuring the oyster knife could fulfill its innovative potential and reach consumers worldwide.
Part 2 – Reason why the customer chose us
Supplied 3D rendering images
Shieldon provided 3D rendering images and addressed key design concerns, focusing on optimizing the knife’s structural integrity and aesthetic appeal.
Key adjustments included shortening the blade and refining the handle for ergonomic efficiency while maintaining the design’s elegance. The challenge of integrating a corkscrew was also addressed, ensuring a balance between functionality and design integrity.
Throughout the process, both parties maintained open communication, exchanged ideas, and resolved issues collaboratively. Shieldon’s approach was rational and function-driven, while the French partner focused on design and ergonomics.
They aimed to create a practical and visually appealing product by valuing both perspectives.
Supplied Pantone color selection
The French partner valued Shieldon’s functional approach, which complemented their design emphasis, ensuring practicality and visual appeal. Pantone color selections were provided for aesthetic alignment, highlighting the importance of detail in design.
As the prototyping phase advanced, the partner appreciated the realization of their vision, emphasizing the critical role of open communication and the integration of diverse perspectives.
This collaborative effort laid a strong foundation for a successful product launch, reflecting a shared commitment to excellence in the global market.
Supplied packaging design and making
The French partner appreciated Shieldon’s dedication to the project, including its willingness to adjust profit margins to foster a lasting partnership. This decision emphasized the importance of maintaining product integrity while addressing market demands.
Shieldon also provided the complete packaging design, ensuring the final product was functional and visually appealing. The collaborative effort underscored the value of communication and flexibility, paving the way for successful production and distribution.
Both parties shared a vision of mutual benefit and market success. The French partner expressed eagerness to begin production and ensure profitability for all involved. This collaboration is a model of effective partnership in the competitive global market.
Part 3 – Story of Manufacturing Process
At the very beginning, the customer presented a plastic prototype. He mentioned that he had modified the design several times but could not create STEP/CAD files and had limited knowledge of how to improve the design further. Additionally, he was unfamiliar with modern production technology. After much consideration, he sought help from an OEM manufacturer to adjust and produce the product.
The customer was also unsure about the minimum order quantity (MOQ) and how to sell the product. In summary, he considered himself new to the industry but was passionate and eager to learn and move forward.
When the customer first contacted Shieldon, he had numerous questions about his product. Shieldon accepted the new project as a professional manufacturer and began by understanding how the product was used and what the customer aimed to achieve.
The customer introduced his design for an oyster knife, which was different from others on the market. The French use oyster knives to skillfully shuck oysters by inserting the knife at the hinge and twisting it to open.
Oysters are enjoyed raw with lemon or mignonette sauce or baked with herbs and butter for extra flavor. Often served during festive meals, especially holidays, the French take pride in regional varieties like those from Brittany or Arcachon.
Oyster knives, with short, sturdy blades, are perfect for opening shells. After shucking, oysters are usually served on crushed ice to stay fresh and enhance the dining experience.
Initially, the design featured a metal steel piece at the top of the item for the thumb to rest on, with a corkscrew hidden at the bottom. The French typically pair oysters with white wine or Champagne, as these beverages complement the delicate flavors of the seafood.
Red wine is less common due to its robust profile, which may overpower the oysters. However, some may choose a light-bodied red with low tannins for a unique pairing experience, enjoying the contrast between flavors while appreciating regional culinary traditions.
After carefully analyzing the structure of the design, a few issues were identified.
First, attaching a curved steel piece to the top of the item proved difficult. If it were to be fixed, two screws would be needed, as shown in the photo. However, these screws could be too large and could damage the item if they were fastened to the handle. If the handle were made of wood, this process could compromise the structure and density of the wood, making it prone to breakage in future use.
The team considered various alternative methods to secure the curved steel but could not find an effective solution. As a result, they informed the customer that the design could not be realized.
Secondly, designers found insufficient space to place a corkscrew at the bottom of the item. The photo shows that the corkscrew could protrude from the handle. If the handle were made of wood, they would need to install the corkscrew head inside the handle, which was not feasible.
Similarly, adding components to the wooden handle would compromise its density.
Another design issue was a gap between the wood handle and steel, which could cause seepage and fail to protect the item. The customer, lacking experience, asked about these design flaws multiple times. Shieldon analyzed the situation and explained the potential problems. The customer, new to the industry and eager to learn, was receptive. With this understanding, the design changes were made.
After discussions, the design was changed to include a large steel piece on the wooden handle, giving it a high-end look. However, the steel risked detaching without screws, and adhesive was unreliable for such a large piece. The design also lacked aesthetic appeal. Shieldon concluded it was not viable for production due to these issues. The customer had a strong vision but overlooked practical manufacturing limitations. Shieldon’s team explained why the design was unfeasible and outlined the production realities.
The best way to test the design’s functionality and feel was to create an inexpensive and quick 3D resin sample. Made through plastic printing, the sample provided a tangible version of the design, making it easier to assess and identify improvements.
This step was necessary for most OEM projects and offered for free. Shieldon used resin samples to help bring customers’ imaginative designs to life, consistently going beyond their initial vision to provide the best suggestions and experience.
The customer requested suggestions for wood handles and patterns. While Shieldon had some wood handle options, wood varied considerably, making it difficult to offer specific recommendations.
Only a few types, like beechwood and olivewood, were shown. However, Shieldon did not recommend using wood for the oyster knife handle due to the following:
- Moisture absorption leads to swelling, cracking, or warping.
- Maintenance requirements, such as oiling, to prevent damage.
- Durability concerns, as wood is less resistant to impacts than synthetic materials.
Additionally, screwing into a wood handle could compromise its structure.
Resin wood handles are commonly used in kitchen knives because they offer:
- Moisture resistance, preventing issues like swelling and warping.
- Enhanced durability, making the wood more resilient to wear and impact.
However, Shieldon disregarded this option for the customer’s oyster knife design, as it did not match the desired appearance.
The customer inquired about using hollow metal steel for the handle. While this material offers benefits such as:
- Excellent weight balance, improving ease of use.
- High durability, resistant to wear, and suitable for heavy use.
The high production costs for this design-led Shieldon to reject the option.
Shieldon decided to adjust the blade design by removing the steel from the top and instead inserting the blade inside the wood handle. This eliminated the need for screws, which improved the design. However, other issues arose, and further discussion with the customer was necessary. Initially, 7Cr17MoV steel was chosen for the blade. As for the corkscrew, no feasible way to incorporate it was found, and it was removed from the design. The corkscrew appeared to be unnecessary, making the item more vulnerable. After discussing it with the customer, he agreed to remove the corkscrew.
After initial discussions, Shieldon provided the customer with structural and 3D rendering images. The structural images covered size, color, and basic features, while the 3D renderings showed the product’s appearance.
These visuals allowed the customer to confirm details. Most customers request small adjustments after reviewing, which is ideal since changes during production can add costs. However, it is always preferred to communicate adjustments before prototyping. Shieldon is experienced in this process and focuses on exceeding customer expectations.
The customer requested adjustments to the design, including a longer blade with a pointed tip for piercing oysters and enough thickness to pry shells open. He emailed how these changes would improve usability for the target market. Further discussions were held to ensure that Shieldon understood the vision and that the customer’s ideas were incorporated into the blade modifications.
Shieldon modified the blade by chamfering the edge to make it less sharp. Two screw holes were added to secure the blade inside the wooden handle, which was the most cost-effective option. At the customer’s request, jimping was added to improve ergonomics. This feature allows users to rest their thumb on the blade for better control while opening oysters, preventing slips. Shieldon values ongoing communication with customers during the modification process, as it helps improve and refine the design. Every Projeto OEM is unique, and feedback is crucial before finalizing production details.
Once the design was confirmed, Shieldon cut out the blade shape, which closely matched the CAD file. This is a testament to Shieldon’s capabilities, as the team handles over 20 OEM projects annually. While the process is familiar, the R&D engineers support the sales team to ensure precise production. The CAD files were passed to the workshop, which created the blade shape accordingly. After this, the customer reviewed the product. However, this was just one phase of the larger OEM project, and many challenges remained.
The customer requested that both edges of the blade be sharp but not razor-sharp. Communication is key in these situations, especially since most of Shieldon’s customers are international. Trust is crucial, and email is the primary method of communication. If customers struggle to express their ideas, sending photos helps ensure clarity. This approach avoids misunderstandings and ensures the final product meets customer expectations.
The customer also had specific requests for the blade tip, which was more challenging to communicate through words alone. He asked for the tip to be less pointed to avoid breakage but still thin enough to pierce and pry open oysters. Shieldon might not have fully understood the request if the customer had only used words, leading to wasted time and effort. The customer clarified the desired tip shape by sending a photo and a few words, which helped ensure the blade met his expectations.
The team began assembly once all components were made, which happens only during prototyping. OEM prototyping is experimental, as results can be unpredictable with new designs. During this project, Shieldon experts found the hole in the wooden handle was too small for the screw. Forcing it in caused it to break, so the team adjusted the hole size to fit correctly. This issue is common in production, as hole sizes often need tweaking. Shieldon professionals updated the data to prevent it from happening again and informed the customer of the changes.
The production process needed to be explained to the customer to build confidence in the manufacturing techniques. The customer was informed that water grinding was used to mill the blade’s edges in this case. This process left a water grinding line on the blade, which could be manually removed. Machine milling operates based on precise data, ensuring consistent results, whereas manual milling is less controlled and can lead to variations. Since manual work is more expensive, machine milling was recommended unless manual work was explicitly required.
After sharpening the edges, the team needed to demonstrate the sharpness to the customer. Since photos couldn’t effectively convey this, a short video showed paper being slashed to highlight the edge’s sharpness.
There was some internal debate about the required level of sharpness. The team believed the edge didn’t need to be extremely sharp, as the knife was designed to pry open oysters rather than cut them.
A sharper edge could break during the prying process. However, the customer argued that a sharper edge would help cut the oyster’s root inside the shell, making it easier to remove the meat. Ultimately, the team agreed with the customer, recognizing his understanding of the market and how the oyster knife would be used.
A discussion arose regarding the groove on the wooden handle, designed for the user’s index finger. To ensure smoothness, the area was slightly rounded. The customer requested this adjustment to avoid any discomfort during use. The professionals confirmed that the modification could be made, but it would incur additional costs due to the extra milling time required. The project was still in the prototype phase, so the team focused on exploring cost-saving measures for future iterations. Additionally, the logo engraving on the handle was addressed. Though no issues were identified, the logo’s placement was adjusted in later modifications.
The size of the rounded area was shown to the customer, though it was a minor change that didn’t require approval. Nonetheless, the professionals kept the customer informed of the adjustments. The customer had no objections to the change. Shieldon professionals always prioritize aligning the product with the customer’s vision and requirements, ensuring it resonates with the target audience. Shieldon offers continuous support to guarantee customer satisfaction and success in the marketplace.
The sharpness of the blade edge was compared. On the left side, the edge was sharp but prone to breakage when prying. On the right, the edge was thicker and more durable, though it might not effectively cut the oyster’s root inside the shell.
The customer initially requested jimping on the blade, but discussions led to a proposal for an alternative solution to save costs and address production difficulties. The team suggested adding a protruded line on the blade for anti-slip functionality. While the customer and the professionals had differing opinions, the team ultimately adhered to the original design, incorporating the jimping as requested. Shieldon values open discussions and strives to balance design preferences with cost-saving solutions during OEM projects.
A video was provided to the customer, showing the physical prototype created from the CAD file design.
When words are insufficient, sending photos or videos is the most effective way to communicate needs and clarifications.
After the prototypes were completed, both parties identified areas for modification. One issue was the 90-degree angle between the wooden handle and the blade, which caused an aesthetic issue and a small gap, risking water infiltration. To resolve this, the area must be milled to a round shape and sealed to prevent corrosion, especially from salty oyster water.
Another modification involved adjusting the blade’s water grinding line. It was positioned too far out and needed to be moved inward to allow more space for beveling. The customer wanted a larger bevel to improve the blade’s ergonomic design, making it easier to pry open oysters.
Another modification involved a gap between the blade steel and wooden handle due to production tolerance. Despite precise machining, such gaps were unavoidable. Sealing the gaps with gel would require handwork, increase costs, and affect the product’s appearance. After discussions, a solution was found to eliminate the need for gel and avoid extra fees by changing the blade’s structure.
The solution involved adjusting the blade’s structure, where the blade was inserted entirely into the wooden handle, eliminating any visible gap. The connection between the handle and blade was altered to avoid using screws, which could potentially damage the wood. This change improved the product’s design while reducing the risk of breakage, offering a practical solution without increasing costs.
The prototypes used 3D-printed resin to mimic the wood color and texture.
While the feel differed from the wood, the customer was persuaded to accept this solution after careful consideration. Shieldon professionals often consider factors beyond design, including cost, technique, lead time, and the customer’s patience. The team aimed to push the project forward efficiently, ensuring it fit into the production schedule without causing delays.
Shieldon’s OEM project service is dedicated to bringing unique designs to life while balancing cost and quality. With expert guidance, Shieldon ensures that projects are completed efficiently, helping brands lead in the market.
Once the prototypes were completed, Shieldon assisted with packaging design and printing. A simple color box with a euro hole was chosen instead of premium options like a lid-and-base box to reduce costs. The euro hole allows products to be hung on store display hooks, enhancing visibility and accessibility. The customer appreciated this cost-effective solution, as they were unsure about packaging options.
The customer provided the design for packaging to be printed on the box surface. Shieldon requested a high-definition file for printing.
Recognizing packaging’s importance in both protection and marketing, Shieldon offers several benefits:
- Market Appeal: Attracts consumers and influences purchasing decisions.
- Cost Efficiency: Integrates design and production to reduce costs and timelines.
- Sustainability: Provides eco-friendly options for environmentally responsible products.
These services ensure cohesive branding and a strong product presentation.
Shieldon offers a variety of packaging options for OEM customers. When detailed descriptions are challenging, photos or videos are the best way to illustrate packaging choices.
The idea of a drawer box and premium gift box was presented to the customer through videos to illustrate packaging options.
As the project timeline extended, some details were forgotten, such as the reason for changing the handle material to plastic (POM) instead of wood. While wood is high-class, it’s difficult to process. A photo was shared showing how the irregular wooden handle was hand-ground, including concerns about the screws’ appearance. When verbal explanations via email weren’t sufficient, pictures and videos were used to communicate challenges and solutions better, explaining that adjustments were necessary to meet modern production capabilities.
Visual aids, such as photos and videos, proved crucial when verbal explanations fell short. These tools helped communicate production challenges and proactive solutions. Shieldon and the customer were concerned about the production process, but the customer was reassured that every avenue was being explored to meet expectations. Despite technological limitations, adopting innovative solutions was key to pushing the project forward and ensuring success.
A preliminary prototype was used to test the functionality of opening an oyster.
A 3D resin sample was created to confirm the appearance before production.
Previous examples of products made from POM demonstrated its reliability as an alternative to wood. The explanation covered the technical process, surface quality, and cost benefits, showcasing expertise.
The plastic injection process includes:
- Material Selection: Choosing thermoplastic materials like POM for desired strength, flexibility, and finish.
- Melting: Heating plastic pellets until they melt into a fluid.
- Injection: Injecting molten plastic into a mold under high pressure.
- Cooling: Letting the mold cool and solidify.
- Ejection: Removing the solidified part from the mold for finishing.
Disadvantages of the plastic injection molding process include:
- High Initial Cost: Designing and producing molds can be costly and time-consuming, making it less cost-effective for low-volume production.
- Design Limitations: Complex shapes are possible, but features like undercuts can complicate the process and require additional mold components.
- Material Constraints: Not all plastics are suitable for injection molding, and some may not meet desired aesthetic or functional standards.
- Quality Control: Issues like warping or shrinkage can occur, requiring strict quality control to maintain consistency.
Part 4 – Shipment and Summary
In concluding the OEM discussion, Shieldon and its French collaborator demonstrated the synergy between functionality and innovative design. Throughout the collaboration, Shieldon provided key insights to optimize the knife’s structure for compatibility with modern production techniques.
By carefully analyzing the design, Shieldon guided adjustments that preserved the aesthetic appeal while enhancing practicality. The mutual decision to refine the blade length and handle ergonomics ensured the product combined elegance and functionality, which was in line with the original vision.
After final adjustments, the prototypes were packed and shipped to the customer using optimal delivery methods, showcasing Shieldon’s commitment to providing exceptional OEM service for all clients.
The customer appreciated Shieldon’s meticulous approach, emphasizing the importance of blending ergonomic design with practical utility. This collaboration highlighted how engineering precision and creative design could combine to produce a product ready for the modern market.
The vision behind the partnership was clear: to create a product meeting high design and functional standards, setting a benchmark for future collaborations. This project improved production capabilities and laid the groundwork for ongoing innovation and market success.
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