Custom Injection Molding For Developing an Eco-Friendly Hotel Soap Dish

Developing an Eco-Friendly Hotel Soap Dish for a U.S. Client

A U.S.-based client approached FCE to create an environmentally friendly hotel soap dish, requiring the use of ocean-recycled materials for injection molding. Starting with the client’s initial concept, FCE managed the entire project, including product design, mold development, and mass production.

The soap dish features a dual-purpose lid that acts as a cover and flips over to function as a draining tray. However, the lid's thickness of 14mm posed a significant technical challenge. Its design lacked internal ribs, and despite using a high-tonnage injection molding machine to fully form the part, the excessive thickness led to post-molding shrinkage and deformation. This deformation caused a "seesaw" effect, where the lid would not lie flat and became stuck when sliding into place.

To address this, FCE applied an innovative restrike process alongside injection molding. After the lid was molded, an additional compression step was introduced to counteract the deformation. This process ensured the lid maintained its flatness, resolving the functional issue and enhancing the product's usability. FCE’s team refined the process parameters and mold design multiple times to achieve a perfect balance between appearance and functionality.

The final product successfully met the client's design goals and was brought into mass production. This innovative soap dish highlights both environmental sustainability and practical functionality, offering a valuable solution for the hotel supplies market.

About FCE

Located in Suzhou, China, FCE specializes in diverse manufacturing services, including injection molding, CNC machining, sheet metal fabrication, and ODM box build services. Our team of seasoned engineers, with decades of experience, utilizes 6 Sigma management practices and professional project management to deliver outstanding results tailored to your needs.

Partner with FCE for precision manufacturing excellence. Our experts can assist with material selection, design optimization, and ensuring your project meets the highest standards of quality and innovation.