Custom Dual-Sided Hair Sponge Project for U.S. Distributor | Fast Prototyping, OEM Precision & Reliable Bulk Delivery

We received an inquiry through our official website from a U.S.-based wholesaler specializing in professional hair care products. The client was looking for a customized Hair Sponge (curl sponge) and provided detailed technical drawings, including exact dimensions, structure design, and packaging specifications. This level of clarity allowed us to move quickly into development with minimal back-and-forth.

According to the client’s requirements, the product was designed in an oval shape with a dual-sided functional structure:

• One side featured a flat PU sponge with large holes for loose curl styling.
• The other side was a wave-textured PU sponge with smaller holes for tighter curl definition.
  Both sponge layers were made of high-quality black PU material to ensure durability and elasticity.

For the internal structure, the client specified a laminated core using a three-layer EVA configuration (blue-black-blue) with a total thickness of 5mm. This EVA core serves as a reinforcement layer, ensuring strong bonding between both PU sponge sides while maintaining flexibility and structural stability during use.

Based on the technical drawings, we quickly developed a dedicated die-cut mold (1-cavity tool) tailored to the product shape. At the same time, we sourced and customized the PU and EVA materials strictly according to the client’s specifications. For packaging, we coordinated with our downstream packaging partners to produce samples that matched the client’s branding and retail requirements.

Within approximately one week, we completed the full sample development, including product and packaging. The samples were shipped via international express and delivered to the client within 7 days. Upon receipt, the client conducted testing and was highly satisfied with the product quality, design accuracy, and overall feel.

Following sample approval, the client confirmed the order quantity and proceeded with a 30% deposit via T/T. We immediately arranged mass production and completed the order within one week, thanks to our efficient production system and prior preparation during the sampling phase.

Before shipment, we provided detailed photos and quality inspection records for the client’s confirmation. After approval, the client paid the remaining 70% balance. We then arranged shipment to the client’s designated freight forwarder warehouse.

Approximately one month later, the client successfully received the goods in the United States and expressed strong satisfaction with both product quality and our end-to-end service. This project not only demonstrated our capabilities in OEM customization and rapid execution but also laid a solid foundation for long-term cooperation.