Custom Silicone Shampoo Brush Head | Italian 2026 Project
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Product |
Silicone Scalp Massager Shampoo Brush |
|---|---|
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Order Quantity |
Initial Order: 45,000 pcs |
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Material |
Food-Grade Solid Silicone |
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Key Specs |
Hardness: Shore A45 Temperature Resistance: -40°C to 220°C |
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Certification |
FDA, CPSIA, REACH Compliant |
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Lead Time |
DFM Evaluation: 24 hrs |
Project details
An Italian home care brand planned to develop a soft-touch silicone brush head that can be filled with shampoo to care for the scalps of infants and adults. The client’s existing sample had an exquisite appearance, but some issues: the massage teeth were prone to breakage at the base, and the outer edges warped and deformed.
Z.S.R addressed the shortcomings of the sample by issuing a DFM assessment within 24 hours, optimizing the massage tooth structure, wall thickness, and reinforcing ribs, and adding a liquid reservoir and outlet. The finished product passed all safety tests, meeting customer requirements.
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
Optimized Rounded Corners at the Massage Tooth Roots
The massage tooth root transitions from a right angle to a 0.8 mm rounded corner, with the wall thickness increased to 3.0 mm. The tooth tips are gradually thinned to 1.6 mm, and the spacing between teeth is adjusted to 2.5 mm.
When massaging the scalp, the massage teeth are subjected to pressure and bending. Right-angled tooth roots concentrate stress and are prone to breakage under repeated stress. The rounded corners at the tooth roots, combined with thicker tooth roots, distribute the stress throughout the entire circumference of the tooth root, extending the lifespan of the massage teeth. The gradually thinning tooth tips ensure a soft and comfortable feel when in contact with the scalp.
Circular Reinforcing Ribs + Unified Wall Thickness
The engineering team unified the brush head wall thickness to 2.2 mm, reduced the amount of material in thicker areas, and implemented a 1.5° draft angle. The height of the reinforcing ribs was reduced from 1.2 mm to 0.8 mm, while the width was increased, and they were changed to continuous circular ribs to balance the overall shrinkage rate of the brush head.
The original design’s straight high ribs and significant differences in wall thickness resulted in uneven shrinkage and stretching during cooling, causing the outer ring to warp after the release of internal residual stress. The uniform wall thickness, low and wide continuous annular ribs, and reduced draft force ensure even shrinkage, improving the product’s stability when laid flat.
New Liquid Reservoir, Injection Port, and Outlet Channel
Z.S.R designed a closed liquid reservoir with a capacity of 12 ml inside the product, with a wall thickness of 2.2 mm. A one-way valve injection port with a valve plate thickness of 0.8 mm is located on the back of the product, which automatically closes after shampoo is injected. An outlet hole with a diameter of 0.6 mm at the root of the massage teeth connects to the liquid reservoir with a multi-channel diversion design. Pressing the brush head deforms the reservoir, and the liquid flows out from the small holes at the root of the teeth.
The uniform wall thickness of the reservoir prevents deformation during molding and cooling. The one-way silicone valve inlet facilitates the addition of shampoo, automatically sealing upon release and preventing leakage even when inverted. The rounded channels reduce dead zones, minimizing shampoo residue and clogging of the small holes.
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 brush head mold making. The mold features a core-pulling structure to create 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 30,000 silicone brush heads within 20 days. Over 10 printing and spraying production lines also allow for printing logos or patterns on the silicone brush heads.
Secondary Vulcanization
After molding, the silicone brush heads 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
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Test |
Condition |
Acceptance Criteria |
Result |
|---|---|---|---|
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Massage Tooth Bend Fatigue Test |
Repeated pressing and bending of massage teeth for 5,000 cycles |
No cracks, breakage or whitening at tooth roots |
Pass |
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Reservoir Leakage Test |
Reservoir fully filled with clean water, inverted and left to stand for 24 hours |
No leakage from fill port, reservoir body or dispensing holes |
Pass |
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Press Dispensing Test |
3,000 press cycles on the brush head, with shampoo filled inside the reservoir |
Smooth liquid dispensing, no spouting or blockage |
Pass |
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Temperature Resistance Test |
20 high-low temperature cycles between -40°C and 200°C |
No deformation, cracking or hardening |
Pass |
|
Flatness / Warpage Test |
Placed flat on a horizontal surface, left at room temperature for 24 hours |
No edge lifting, stable placement without wobbling |
Pass |
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Dimensional Inspection |
Diameter, wall thickness, tooth height and reservoir dimensions measured with caliper |
All dimensions meet ±0.15 mm tolerance |
Pass |
|
Visual Inspection |
Full visual inspection of product surface |
No material shortage, bubbles, flash or scratches; outer contour is smooth and complete |
Pass |
|
Hazardous Substance Test |
Chemical composition testing |
Compliant with GB 4806.11, RoHS and REACH requirements |
Pass |
The production samples passed the specified tooth bend fatigue, 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 cycles on the massage teeth.
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Customer reviews & feedback
“After all this time, the materials have finally arrived at R. I would like to express my sincere gratitude to your company, all the employees involved in production, and especially Ms. Elaine, who worked directly with us! It was a very pleasant experience working with her. We are very grateful to your company for resolving the issue so quickly and efficiently!”
Custom Silicone Shampoo Brush
OEM & ODM solutions for brands, retailers, wholesalers, and Ecommerce sellers. Food-grade silicone shampoo brushes with FDA/CPSIA/REACH compliance.
Other Project
For industrial-scale production, ZSR Group also operates a dedicated silicone compression molding service for custom silicone parts.
