From Prototype to Mass Production: The Journey of a Creative Product

very product in our daily lives—whether a soft bedside lamp or a compact handheld fan—starts from a simple idea and goes through a complex journey before reaching the user. The path from prototype to mass production is the foundation of creative product development. At TaoYiXuan Electronics, we’ve brought to life many OEM product manufacturing projects by turning small inspirations into scalable solutions.

The idea for our handheld fan was born from observing users’ real needs—especially the modern demand for multifunctionality and portability. During hot summer nights, users often need both cool airflow and soft lighting. Combining the two functions created an innovative yet practical product.

The creative product development process begins with brainstorming and concept design. Our team of designers, engineers, and marketers collaborate to explore ideas: how to make the fan lighter, how to control the light’s brightness, and how to support USB charging. Market analysis and user research are conducted in parallel, ensuring the product concept aligns with trends and demand.

Once the concept is clear, we move to prototyping. Using 3D printing and CNC technology, we quickly create samples to test functionality, ergonomics, and design. For example, we test different blade shapes for airflow, evaluate the light’s color temperature, and check the tactile feedback of each button. Prototype testing allows us to verify and improve every detail before investing in tooling.

After multiple refinements, the project enters the OEM product manufacturing process. We begin with mold development—critical for ensuring structural precision and high yield. For our fan-lamp product, we chose high-strength ABS material with flame-retardant properties to meet safety and RoHS environmental standards.

Once molds are completed, we conduct small-batch trial production—typically 500 to 1,000 units—to test the stability of the production line and identify potential assembly or quality issues. During this phase, we also collect user feedback. For instance, users once found the power button too hard to press, which we solved by adjusting the spring structure.

When all systems are optimized, we scale up to full mass production. TaoYixuan’s factory is capable of producing 800,000+ units per month, combining automated equipment with skilled labor. Each unit goes through strict quality control, from raw materials (IQC), in-process inspection (IPQC), to final and outgoing quality control (FQC & OQC). All products are tested for fan speed, light function, durability, and meet international certifications such as CE, RoHS, and CCC.

The final stage is packaging and market launch. We designed recyclable paper boxes with protective linings that not only ensure transportation safety but also convey the brand’s environmental values. Before shipment, we verify packaging integrity, label accuracy, and compliance with export documents. We also support clients in launching their products through social media marketing, trade shows, and KOL collaborations.