Toy Manufacturing at Double E Toys

Let's take a look at each of these steps and break them down into smaller stages which are necessary for achieving the best possible outcome. Before we start, please keep it in mind that the toy manufacturing process described below is simplified in order to make it easy to follow and understand.

How toys are made? The process starts with market research

Before a factory begins manufacturing a new toy, product development team should determine whether there is a market for the product idea. This process is known as market research. In general, market research helps a toy manufacturer to assess consumer demand, identify potential competitors, set the best price point for the new toy, and determine most suitable new toy supply chain. Although market research is time-consuming and expensive, it is essential for making informed decisions about which toys to produce. By conducting thorough market research, toy manufacturer minimizes a risk of costly mistakes and maximizes the chances of a particular venture.

But since Double E toys are sold internationally, we as toy manufacturer often take more flexible approach and some of remote control trucks are developed and manufactured in ventures with our toys distributors operating in different countries or geographical areas and sold under double brand. This kind of business venture may take different forms depending on negotiations between both parties. The Ursus-360 remote control tractor model, which was developed together with our Polish toy distributor Ata Swiat Modeli i Zabawek has been one of the most recent and successful toy manufacturing ventures.

Toy manufacturing - design and prototyping

Toy prototype design and making

The first step in the process of designing toys starts with 3D modelling. This allows for virtual model creation and visualization that can be explored from all angles before any prototype is build.

After the 3D toy model is finalized, it's time for prototype building. The goal of toy prototyping is to produce a working sample of the toy that can be used for testing and evaluation to identify potential problems during toy manufacturing process or problems with the final product. Once the prototype is printed, it's time to assemble it and test if the construction of the toy is suitable for the mass production.

At Double E this typically involves putting together the different parts of a RC toy trucks, such as the chassis, wheels, electric board and truck's body.

Toy prototype durability and safety tests - quality control

By running a series of durability and safety tests on a prototype, R&D (research and development) team can identify any potential problems and make the necessary changes before the prototype is approved and toy manufacturing moves down the process ladder. That's why regular toy prototype testing consists of three intense scrutiny rounds. In the first stage, the toy's functionality is tested to make sure that toy works as it is expected. In the second stage, the toy goes through a series durability tests to make sure it can withstand rough play over time. And in the third and final stage, a series of safety tests is conducted, including physical and mechanical hazards, to ensure that the toy is safe for use by children.

Double E Toys team is always mindful of the safety precautions we need to take when designing and manufacturing toy for our little customers. We have a separate post that covers this topic including RC toy safety guidelines and advice for parents, so be sure not miss out on this valuable resource!

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Toy manufacturing - legal protection

In most of cases, before moving on to the following toy manufacturing phase, the final toy prototype is reviewed by international lawyers for pattern and copyrighting protection, to ensure that the toy does not infringe any existing patents or trademarks. It also may include toy licensing agreements that are usually checked by lawyers to make sure they are fair and legal. This process is important to protect the interests of both the toy manufacturer and the licensor. The agreement usually stipulates how many toys can be manufactured, what geographical area they can be distributed, and how long the toy licensing agreement will last.

License not only makes Double E remote control trucks more realistic, but it also allows for better advertising and higher sales volume. Successful toy license approval, requires the toy to meet certain toy manufacturing quality standards and safety requirements set forth by the licensor.

At Double E Toys, we are always looking to expand our licensed toy collection. We work with some of the biggest names in the automotive industry to bring our customers the latest and greatest licensed remote control trucks and cars. Double E group is a licensee for many famous names, including: Mercedes-Benz, Land Rover, JCB, Humvee, Jeep, Citroen, Toyota, Mazda, Suzuki, Mack, Lotus and others.

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Toy manufacturing -mold production

Injection molding is one of the most popular toy manufacturing solutions. Mold production begins with a 3D mold completed by a skilled design engineer. After, the testing mold sample is made in order to test the quality and dimensions of the toy component. The molding parts are usually made from aluminum, steel, or alloy. It is a very slow and meticulous process, often taking weeks or even months to complete. Injection molding is in high toy production demand because the same toy can be reproduced thousands of times. The injection molding process is also relatively quick and requires little manual labor, which makes toy manufacturing cost-effective.

Double E group has established its mold production department 30 years ago. Since then the  department grew to 34 professional mold engineers and 31 mold production machines with production capacity of 10 new molds every month. The department is big enough to solely produce all molds needed to expand selection of products to keep up with the latest trends in the toy industry.

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Toy manufacturing - packaging design

Designing the packaging for toys can be quite a challenge. This is because there are four major factors that need to be taken into account - material, function, size and messaging.

Toy packaging materials challenge

In the toy manufacturing industry, there are a variety of different packaging materials that can be used. However, in recent years there have been a few additional considerations that need to be taken into account. In addition to toxic-free material an eco-friendly packaging is becoming increasingly popular as consumers become more conscientious not only about kids safety but also about the environment protection. As a result, toy packaging materials should be durable, safe for children and the environment.

Toy packaging function - transport, stack and re-use

The major role of packaging is to protect toys during transportation and stacking but also the packaging should help to keep a toy clean. In addition, it is very important that the box is reusable because many parents may want use it for toy storage or potentially re-gift once children forget about the toy.

Toy packaging size matters

With transportation costs getting high and buyers wanting more compact packaging that can be shipped easily across countries - packaging size needs much more attention and creative mind. But at same time having too small box might have negative effects on direct sales through vendor or supermarket shops as younger kids often like bigger things as they get more exciting about what's inside the box. Right toy packaging should balance between transportation cost and attractive appeal that will boost kids' interest in a toy.

Toy packaging message - getting kids excited

The colors and images on toy packaging play a significant role in the purchasing decisions of parents and children. Bright colors are often associated with fun and excitement, while soft colors can convey a feeling of safety and comfort. Images of appealing scene with the toy also help to grab attention and create an emotional connection between potential customers and a toy. In many cases, the colors and images on toy packaging are the first things that a child will notice.

Interested in a new RC excavator? Check out our dedicated post.

The Double E design team is a group of highly dedicated and experienced toy packaging designers that are committed to creating the best possible packaging for our clients' products.

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Toy manufacturing - production phase

Toy parts and components production

The process of toy production begins with selection of well examined and toxic free ABS plastic materials. Before molding process begins, ABS pellets are dried in special machines. The ABS is then transferred to the molding machines and the pellets are heated until they become liquid, then injected into a mold where it's forced out through tiny holes. The plastic cools and solidifies, taking on the shape of the mold cavity. The mold is then opened and perfectly formed toy part is ejected.

The amazing thing about ABS material is that it can be melted down and reshaped over again without significant chemical degradation, making it recyclable. ABS plastic material offers a great balance of dimensional stability, tensile strength and electrical characteristics which makes it strong.  

All of Double E toys are manufactured from tested and certified raw materials.

Shenzhen Toy Fair has become on of the most important events in China. This year China Toy Association has nominated Double E products for our commitment to quality and authenticity. Read more - Shenzhen Toy Fair Awards.

Toy assembly

As anyone who has ever put together a toy knows, the assembly is critical to the success of the toy manufacturing process. Any mishandling of the toy parts can result in defects what will ultimately be passed on to the end-users. To prevent this, toys are assembled according to tested instructions which guide the assembly lines. In addition, it is important that workers who are assembling toys are properly trained and strictly follow the rules.

The Quality Check department is responsible for testing toys after they are assembled. This important task helps to ensure that products meet safety standards and are free of defects. The department typically consists of professionals with extensive knowledge of toy manufacturing process. In order to test toys, the QC team uses a variety of methods, including visual inspection and functional testing.

After that, assembled toys are sent down to the packaging department. The packaging team makes sure each toy is securely packed in the appropriate box with all the needed manuals and instructions.

The products are stored at the warehouse until they'll be distributed between toy retailers.

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Double E toys manufacturing capability

As one of the most well-known toy manufacturers in mainland China, Double Toys has been providing high-quality plastic toys to consumers around the world for over three decades. Today, Double E Group has 3 toy manufacturing facilities which cover 50 000 square meters and employs over 1000 employees. Manufacturing facilities are equipped with 228 injection molding machines which allows Double E toy manufacturing capacity to go over 1 million toys per year. In April 2022, CaDA Bricks first fully automated warehouse system has been successfully launched and within next 3 years the company plans to automate whole warehouse facilities.

Double E Toys can be found on each commercial B2C platform and our toys are exported to more than 50 countries around the world. In the last 10 years we have served over 1 thousand B2B customers and sold over 10 million toys. Double E has has thriving partnerships with well known toy companies, including brands like Jamar, Carlson, Smith Toys, Carrefour and Lidl.

‍We're proud that our high standards, expertise and experience in the toy industry has made us one of most often chosen toy manufacturers for OEM products.