// Frolick baby teether
Give them something to drooool over.
We developed a prototype concept into a fully certified, volume-production consumer product. The core challenge was engineering a complex dual-material overmoulded design that needed to be structurally rigid in some areas whilst remaining soft and safe for chewing in others – all while meeting stringent FDA material approvals and passing rigorous choke hazard testing.
The product is now in full volume production and sold worldwide.
// The problem & the solution
The Core Challenge & Solution
The Problem
Bringing a Safety-Critical Baby Product to Market
Dual-Material Design: The product needed to combine a rigid structural core with soft chewable zones - requiring an overmoulding process that had to work consistently in volume production.
Manufacturing Complexity: Achieving reliable bonding between two dissimilar materials in an overmoulding process at scale, without defects or delamination.
Regulatory Compliance: All materials had to be FDA approved and free from harmful substances, with full documentation for market access.
Safety Testing: The geometry had to be engineered to pass rigorous choke hazard standards, requiring careful optimisation of dimensions and form.
The Solution
Precision Overmoulding, Certified for Production
Engineered an innovative overmoulding approach that achieved reliable dual-material construction at volume, with rigid core and soft chewable zones performing exactly as required.
Selected FDA-approved material combinations that met all regulatory requirements whilst delivering the tactile and durability properties needed for a baby product.
Optimised the geometry through iterative design to pass choke hazard and safety testing, giving the client a clear route to market.
Supported the full transition from prototype to volume production. The product is now sold globally by Frolik+Co (frolikandco.com).
// Technical Highlights
Precision Engineering
| Focus | Engineering Action | Result |
|---|---|---|
|
Dual-Material Construction |
Engineered overmoulding process for rigid/soft zones |
Consistent, defect-free production parts |
|
FDA Compliance |
Specified approved material grades |
Full regulatory clearance for baby product market |
|
Choke Hazard Testing |
Geometry optimised through iterative design |
Passed all required safety standards |
|
Production Transition |
DFM-led design and supplier coordination |
Full volume production, sold globally |
// Value Delivered & Results
From Concept to Reliable Tool
For the Client
-
Delivered a certified, production-ready product that passed all safety and regulatory requirements, and successfully launched into the consumer market.
For the End User
-
A safe, FDA-compliant teether with a dual-material design that provides the right stiffness and softness exactly where a baby needs it.
Key Outcome
-
The product is now sold in volume worldwide by Frolik+Co.