Customizing a dive mask for your brand is not a single decision — it is a sequence of engineering, progetto, and production choices that compound into your final product. Each step in the process affects cost, timeline, qualità, and your competitive position.
This article walks you through the entire OEM customization process — from initial design submission to first mass production shipment — with real timelines, milestones, and decision points. We use our own production data as reference, including the DFM feedback turnaround, mold development cycles, and quality checkpoints that define our process.
The OEM Process at a Glance
| Phase | Duration | Key Deliverable | Your Action |
|---|---|---|---|
| 1. Design Submission | Day 1–3 | Technical drawings, 3D CAD files, or reference samples | Send design files or physical samples |
| 2. DFM Feedback | Day 3–5 | Design for Manufacturing report | Review and approve engineering recommendations |
| 3. Mold Development | Day 5–35 | CNC-machined production mold | Wait (or request mold design review) |
| 4. T1 Sampling | Day 35–45 | First-article samples with dimensional report | Review samples; approve or request changes |
| 5. T2 Sampling (if needed) | Day 45–55 | Revised samples | Final approval |
| 6. Pre-production Confirmation | Day 55–60 | Golden sample signed by both parties | Sign off on golden sample |
| 7. Mass Production | Day 60–120 | Finished goods | Arrange QC inspection and shipment |
Phase 1: Design Submission
You can initiate an OEM project in three ways:
- Full technical package: 3D CAD files (STEP, IGES, or SolidWorks format) with 2D drawings specifying dimensions, tolerances, material, colore (Pantone), and surface finish. This is the fastest path — our engineers can begin DFM review immediately.
- Reference sample: Send a physical sample of a mask you want to replicate or modify. Our engineering team will reverse-engineer the dimensions, create CAD files, and propose modifications for manufacturability.
- Concept sketch + requirements: Describe your target market, desired features (per esempio., “low-volume freediving mask with tempered glass and silicone skirt”), and aesthetic direction. Our design team creates initial concepts for your review.
Phase 2: DFM Feedback (24–48 Hours)
Our engineering team reviews your design against manufacturing constraints. The DFM report covers:
| DFM Category | What We Check |
|---|---|
| Wall thickness | Uniform wall thickness for even material flow; minimum 1.5mm for PC frames, 2.0mm for silicone skirts |
| Draft angles | Minimum 1° draft on all molded surfaces for clean ejection |
| Undercuts | Identify undercuts that require side-actions or special mold mechanisms |
| Co-injection feasibility | Verify frame geometry supports silicone co-injection (channel design, surface treatment areas) |
| Parting line | Optimize parting line position to minimize visible flash lines on the finished product |
| Gate position | Recommend gate location for optimal material flow and minimal witness marks |
| Tolerance stack-up | Verify that assembly tolerances between frame, skirt, lens, and strap lugs are achievable |
| Material recommendation | Suggest optimal material grades based on your performance requirements and target cost |
The DFM report includes marked-up drawings highlighting any areas that need modification. Most designs require 1–2 rounds of DFM revision before the design is production-ready.
Phase 3: Mold Development (15–30 Days)
Once the DFM is approved, mold fabrication begins. Our in-house CNC mold development center handles the entire process:
Mold Design (3–5 days)
Mold engineers create the mold flow analysis and mold design package. This includes: cavity layout (single or multi-cavity), cooling channel design, ejection system, side-action mechanisms (if needed), and frame placement fixtures for co-injection molds.
CNC Machining (7–15 days)
The mold block is machined from hardened steel (P20 or H13 grade). CNC milling, EDM (electrical discharge machining), and wire cutting create the cavity geometry to ±0.02mm tolerance. Lens cavities require optical-grade polishing.
Mold Assembly & Testing (3–5 days)
The completed mold is assembled, fitted, and tested on the injection molding machine. Initial shots (short shots) verify material flow, filling pattern, and part dimensions. Adjustments are made until the mold produces parts within specification.
In-house Advantage
Having CNC mold development in-house means we control the timeline. External mold shops add communication overhead and queue delays. Our typical mold lead time is 15–25 days for a standard single-lens mask; 20–30 days for a co-injection mold with frame placement system.
Phase 4–5: Sampling & Approval
T1 Samples (First Articles)
The first samples from the new mold are measured and inspected against the original design specifications. We provide:
- Dimensional report (key dimensions measured with CMM or calipers)
- Visual inspection report (surface quality, flash, sink marks, short shots)
- Functional test (assembly fit, skirt flexibility, lens clarity)
- Material certificates (resin batch, silicone batch, hardness test)
You receive 3–5 samples with the full inspection report. Review the samples against your requirements and provide feedback. Common adjustment requests: skirt softness (adjust silicone hardness ±5 Shore A), strap lug position (±2mm), corrispondenza dei colori (Pantone verification).
T2 Samples (Revision)
If T1 samples require changes, the mold is modified and T2 samples are produced. Most projects complete in 1–2 sampling rounds. Complex designs with tight cosmetic requirements may require 3 rounds.
Phase 6: Golden Sample & Pre-production
Once samples are approved, both parties sign a “golden sample” — the physical reference that defines acceptable quality for mass production. The golden sample is sealed and kept at the production line. Every unit produced is compared against it during QC.
Phase 7: Mass Production (30–60 Days)
Production Schedule
| Fare un passo | Duration | QC Gate |
|---|---|---|
| Material procurement (PC resin, LSR, vetro temperato, cinghie) | 5–10 days | IQC: incoming material inspection |
| Injection molding (frames, skirts) | 5–15 days | IPQC: in-process dimensional checks |
| Lens cutting and tempering | 3–5 days | IQC: lens edge quality, optical clarity |
| Assembly (frame + skirt + lens + strap) | 5–10 days | IPQC: assembly fit, seal test |
| Final inspection | 3–5 days | FQC: 100% visual + AQL functional test |
| Packaging and labeling | 3–5 days | OQC: pre-shipment audit |
Quality Control: Four-Gate System
| Gate | Name | What Happens |
|---|---|---|
| 1 | IQC (Incoming Quality Control) | Raw materials inspected: silicone batch hardness, glass lens edge quality, PC resin grade verification |
| 2 | IPQC (In-Process Quality Control) | Inline checks during molding and assembly: skirt bonding strength, lens alignment, snorkel valve function |
| 3 | FQC (Final Quality Control) | 100% inspection or AQL sampling after assembly: air-tightness test, anti-fog duration test, visual inspection |
| 4 | OQC (Outgoing Quality Control) | Pre-shipment audit: packaging integrity, labeling accuracy, quantity verification, random function tests |
MOQ, Pricing & Payment Terms
| Articolo | Standard Terms |
|---|---|
| MOQ (custom design) | 300 pcs per color |
| MOQ (stock design, custom branding) | 50–100 pcs |
| Mold cost | $1,500–$5,000 per component (depending on complexity) |
| Sample cost | $100–$500 (refunded against first order above MOQ) |
| Production lead time | 30–60 days after sample approval |
| Payment terms | 30% deposit, 70% before shipment (standard); negotiable for repeat orders |
Domande frequenti
Can I visit the factory during production?
SÌ. We welcome factory visits for mold trials, sample approval, and pre-shipment inspection. Schedule at least 2 weeks in advance so we can arrange the production line tour and QC demonstration.
What if I need to modify the design after production has started?
Minor modifications (color change, strap adjustment) can usually be accommodated without stopping production. Major modifications (frame geometry, lens size) require mold changes and a new sampling round. The earlier you finalize the design, the more cost-effective the project.
Do you provide ongoing support after the first order?
SÌ. We maintain your mold in our storage facility. Reorders use the same proven mold — no re-sampling needed unless you request changes. Reorder lead time is typically ~30 days (faster than first order since mold is proven and process parameters are set).
