Custom Silicone Night Light | UK 2026 Project
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Product |
Cartoon Panda Liquid Silicone Tap Night Light |
|---|---|
|
Order Quantity |
Initial Order: 21,000 pcs |
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Material |
Liquid Silicone + Vibration-Sensing LED Components |
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Key Specs |
Hardness: Shore A32 |
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Certification |
REACH, RoHS, EN71-3 |
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Lead Time |
DFM Evaluation: 24 hrs |
Project details
A British home and lifestyle brand was looking to develop a silicone night light with a soft, tactile feel. The light could be switched between different lighting modes by tapping or pressing the body, combining the functions of an ambient decorative piece, a tactile toy, and a functional light.
During the early-stage market research, the client identified three key issues with similar products on the market: homogeneous product designs with low brand differentiation; improper wall-thickness design of the light body; and LED components that were prone to becoming loose during use.
After being introduced to Z.S.R, the client established a partnership. Leveraging 19 years of experience in customized silicone products, Z.S.R’s engineers conducted a comprehensive DFM optimization based on the client’s aesthetic preferences and functional requirements, focusing on four key areas: product design, localized wall thickness, internal LED assembly fixation, and impact-sensing structure.
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
Design Differentiation
Based on the client’s brand preferences, Z.S.R developed a panda-shaped silicone night light with a matte silicone finish. The head-to-body proportions were designed with a soft, rounded, and cohesive appearance.
The silicone night light market is highly homogeneous in terms of appearance. The distinctive panda shape combined with the matte silicone finish helps the client establish stronger visual differentiation and enhance brand recognition.
Wall Thickness Optimization
The wall thickness was carefully optimized for different areas of the panda housing: head wall thickness 2.2 mm, ear wall thickness 2.0 mm, torso side-wall thickness 2.5 mm, and base thickness increased to 3.5 mm. All internal corner radii are R ≥ 0.8 mm.
The 2.2 mm head wall thickness provides a soft tactile feel while allowing moderate deformation when tapped, helping trigger the vibration sensor. The 2.0 mm ear thickness maintains a rounded appearance while reducing the risk of short shots during molding. The 2.5 mm torso wall thickness improves the tear resistance of the side walls. The thickened base significantly improves stability when placed on a surface, and the rounded corners eliminate stress concentration points, reducing the risk of cracking after repeated tapping.
Internal LED Assembly Fixation
Instead of relying solely on adhesive for fixation, Z.S.R adopted a mechanical positioning structure to secure the LED assembly. Snap-fits and locating ribs firmly hold the light base in position, while a 0.15 mm assembly clearance is incorporated to facilitate installation of the LED assembly.
The snap-fit and circumferential locating rib structure keeps the LED assembly securely fixed during use, solving the problem of components becoming loose over time.
Impact-Sensing Structure
To address the tendency of tapping forces to dissipate throughout the silicone body, Z.S.R added shallow internal ribs to directly transfer impact forces to the sensing component.
The shallow internal ribs improve the sensitivity and reliability of light activation, ensuring every tap is accurately registered by the vibration sensor.
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 liquid silicone light mold making. Venting grooves are added to thin-walled areas such as the ears and head of the product, and the front appearance cavity is mirror-polished.
Silicone Molding
Production is supported by 48 solid molding machines, 12 liquid molding machines, and 13 injection molding machines using liquid silicone injection molding for one-piece molding. Over 10 printing and spraying production lines also allow for printing logos or patterns on the silicone night light.
Secondary Vulcanization
After molding, the silicone night lights undergo secondary vulcanization at 200°C for 2 hours.
The secondary curing process removes small-molecule volatiles from the liquid silicone, reduces product odor, and stabilizes the silicone properties.
Quality Inspection
|
Test |
Condition |
Acceptance Criteria |
Result |
|---|---|---|---|
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Light Transmittance Uniformity Test |
Observe light transmission of panda when illuminated |
Uniform overall light transmission, no local bright spots or dark areas |
Pass |
|
Repeated Tapping Fatigue Test |
Continuous tapping ≥5,000 cycles |
No stress whitening, no cracking |
Pass |
|
Thermal Cycling Test |
Alternating environment between -40°C and 120°C |
No aging or deformation |
Pass |
|
Drop Test |
Free drop from 1 m height (10 times each for front, side and bottom) |
No deformation; light assembly stays securely fixed |
Pass |
|
Wall Thickness & Dimension Sampling Inspection |
3D scanning on head, ears and base |
Wall thickness matches design value; dimensions within ±0.25 mm tolerance |
Pass |
The production samples passed the specified light transmittance, tapping fatigue, thermal cycling, drop, and dimensional inspections. In particular, no stress whitening or cracking was observed after 5,000 continuous tapping cycles.
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Customer reviews & feedback
“We received the silicone lights and are extremely satisfied! We love their individual packaging, the printing quality is superb, and the design is very appealing! Thank you so much for the fast production and shipping! We are truly grateful! Our clinic is about to celebrate its fifth anniversary, and our customers will definitely love this gift!”
Custom Silicone Night Light
OEM & ODM solutions for brands, retailers, wholesalers, and Ecommerce sellers. Liquid silicone night lights with REACH/RoHS/EN71-3 compliance.
Other Project
For industrial-scale production, ZSR Group also operates a dedicated silicone compression molding service for custom silicone parts.
