Custom Silicone Body Brush | Australian 2024 Project
|
Product |
Oval Silicone Body Shower Brush |
|---|---|
|
Order Quantity |
Initial Order: 35,000 pcs |
|
Material |
Food-Grade Solid Silicone |
|
Key Specs |
Hardness: Shore A35 |
|
Certification |
GB 4806.11, RoHS, REACH Compliant |
|
Lead Time |
DFM Evaluation: 24 hrs |
Project details
An Australian brand specializing in body care products, particularly silicone bath and body care items, wanted to develop a body brush that could store shower gel and dispense it by pressing the brush body.
The client relayed their needs to Z.S.R, and the engineering team optimized the bristle structure, product wall thickness, and liquid storage system, balancing a soft touch with durability to meet their bathing needs.
Based on the DFM results, the project moved into mold making and sample production, followed by quality verification of the first batch before mass production.
Delivery data
Engineering DFM Assessment
Rounded Bristle Roots + Gradual Thinning Design
The bristle roots were optimized from right angles to a 0.7 mm rounded corner transition, and the bristle spacing was adjusted to 2.2 mm. The bristle roots are thickened to 2.6 mm, and the tips are gradually thinned to 1.4 mm.
During use, the body brush is continuously pressed, causing stress concentration at the right-angled base. Repeated friction and pressure can lead to whitening and breakage. Thickening the base with rounded corners distributes the concentrated stress across the entire circumference, extending the lifespan of the bristles. The thinner bristle tips provide a softer feel against the skin.
Uniform Wall Thickness + Circular Reinforcing Ribs
The engineering team added a 0.7 mm high, widened, continuous circular rib, unifying the body brush wall thickness to 2.0 mm. Thick areas were treated with reduced material thickness, and a 1.5° draft angle was added to the side walls, resulting in uniform shrinkage and a flat, even finished product.
During the silicone molding and cooling process, differences in wall thickness can cause uneven shrinkage, leading to warping at the product edges after stress release. Uniform wall thickness, low-profile continuous ring ribs, and the draft angle minimize warping.
Built-in Liquid Storage Chamber, Injection Valve, and Discharge Channel
Z.S.R incorporated a 15 ml closed-loop circular liquid storage chamber inside the product, with a 2.0 mm wall thickness. A one-way valve-type liquid inlet on the back, with a valve plate thickness of 0.7 mm, automatically closes after shower gel is injected. The base of the bristles has 0.5 mm diameter liquid outlet holes connected to the chamber via multi-branched arc flow channels. Pressing the brush head increases the pressure inside the chamber, and the liquid flows out from the holes at the base of the bristles.
The liquid reservoir has a uniform wall thickness, preventing deformation during molding and cooling. The integrated silicone valve on the back facilitates adding shower gel, automatically sealing upon release and preventing leakage even when inverted. The rounded channels reduce dead zones, minimizing shower gel residue and the risk of clogging the outlets.
Mold Making, Sample Production & Quality Verification
Mold Processing
Z.S.R Group is equipped with 10 advanced CNC machining centers and 4 EDM machines for silicone body brush mold making. The parting surface is integrally ground, and the mold features a built-in core-pulling structure to form the internal liquid storage cavity.
Silicone Molding
Production is supported by 48 solid molding machines, 12 liquid molding machines, and 13 injection molding silicone machines, enabling the rapid molding of 25,000 silicone body brushes within 20 days. Over 10 printing and spraying production lines also allow for printing logos or patterns on the silicone brushes.
Secondary Vulcanization
After molding, the silicone body brushes undergo secondary vulcanization at 200°C for 2 hours.
The secondary curing process removes small-molecule volatiles from the silicone, ensuring safety for skin contact.
Quality Inspection
|
Test |
Condition |
Acceptance Criteria |
Result |
|---|---|---|---|
|
Bristle Friction Endurance Test |
Repeated pressing and rubbing for 5,000 cycles |
No cracks, breakage or significant whitening at bristle roots |
Pass |
|
Reservoir Leakage Test |
Reservoir fully filled with clean water, inverted for 24 hours |
No leakage from fill port, reservoir body or dispensing holes |
Pass |
|
Press Dispensing Test |
3,000 press cycles, with body wash filled inside the reservoir |
Smooth liquid dispensing, no spouting or blockage |
Pass |
|
Temperature Resistance Test |
20 cycles between -40°C and 200°C |
No deformation, cracking or significant hardening |
Pass |
|
Flatness / Warpage Test |
Left at room temperature for 24 hours, then placed flat on surface |
No noticeable edge lifting, stable placement |
Pass |
|
Dimensional Inspection |
Key dimensions measured with caliper |
All dimensions meet ±0.15 mm tolerance |
Pass |
|
Visual Inspection |
Full surface inspection of product |
No material shortage, bubbles, flash or scratches |
Pass |
|
Hazardous Substance Test |
Chemical composition testing |
Compliant with GB 4806.11, RoHS and REACH requirements |
Pass |
The production samples passed the specified bristle friction endurance, reservoir leakage, press dispensing, temperature resistance, flatness, dimensional, visual, and hazardous substance inspections. In particular, no cracks or breakage was observed after 5,000 pressing and rubbing cycles.
Related Silicone Bowl Product
Customer reviews & feedback
“We are very satisfied with this product! Its hardness and color are exactly what we wanted. Best regards!”
Custom Silicone Body Brush
OEM & ODM solutions for brands, retailers, wholesalers, and Ecommerce sellers. Food-grade silicone body brushes with RoHS/REACH compliance.
Other Project
For industrial-scale production, ZSR Group also operates a dedicated silicone compression molding service for custom silicone parts.
