TESDUR Implements Comprehensive Quality Management Upgrade for Liquid Full Encapsulation Production Process
May 2025 – TESDUR Electronic Technology Co., Ltd. has completed a systematic and comprehensive upgrade of its quality management system, with a focused emphasis on the liquid full encapsulation (liquid silicone overmolding) production process. This initiative reflects TESDUR’s ongoing commitment to delivering consistent, market-leading quality to brand partners and wholesalers worldwide.
Background: Why Quality Management Matters in Liquid Silicone Manufacturing
Liquid silicone adult toys have earned a reputation in global markets for their body-safe materials, soft texture, and durable construction. As consumer expectations rise and international compliance standards become more stringent, manufacturers must go beyond basic quality checks—they need structured, end-to-end quality management systems that cover every stage of production.
For brand partners sourcing from China, the encapsulation process is one of the most critical yet complex steps in the manufacturing chain. A single defect in the overmolding stage can affect product safety, waterproof performance, and overall user experience—issues that are difficult to detect after products reach the market.
Recognizing these challenges, TESDUR has invested in upgrading its quality management infrastructure across its 3,000 m² production facility, with particular focus on strengthening the liquid full encapsulation production workflow.
Upgrade Highlights: A Three-Stage Quality Control System
TESDUR’s upgraded quality management system now operates across three core stages—Incoming Quality Control (IOQ), Process Quality Control (PQC), and Outgoing Quality Control (OQC)—covering every step from raw material intake to final shipment.
Incoming Quality Control (IOQ)
Before any component enters the production line, it must pass TESDUR’s standardized incoming inspection protocol. Each batch of incoming materials undergoes structured testing against defined acceptance criteria:
-
Motors: Current measurement (A), sound testing during natural hang-down, and functional run tests with the actual overmolded silicone housing to verify noise levels and vibration performance.
-
Batteries: Voltage verification using a multimeter, dimensional checks with calipers, and出线 length and wire diameter inspection against original sample specifications.
-
PCBs: Functional testing by soldering motors and batteries and powering on; dimensional verification against original samples.
-
Silicone components: Durometer (hardness) testing by hand feel comparison against approved samples; dimensional measurement with calipers.
-
Hardware and accessories: Visual and dimensional inspection, with assembly fit tests on selected components.
All inspection results are documented on paper-based incoming inspection report forms and cross-referenced against each component’s batch number for full traceability.
Liquid Full Encapsulation: Where Quality Management Gets Real
The liquid full encapsulation (包胶) process is the heart of TESDUR’s manufacturing identity. To ensure every overmolded product meets the standards expected by international brands, TESDUR has implemented a rigorous set of controls specifically for the encapsulation stage.
Pre-Encapsulation Machine Inspection
Before each production shift begins, equipment settings—including temperature, pressure, and injection timing—are verified against the approved process parameters for the specific product model in production. Any deviation from standard settings triggers a hold until the root cause is identified and corrected.
In-Process Quality Control (PQC)
During encapsulation production, TESDUR quality inspectors conduct scheduled checks every two hours across all stations. These process cover:
- Operator adherence to the encapsulation operation guidelines
- Correct sequencing of production steps
-
Proper use and calibration of production tooling
-
Intermediate product quality sampling and appearance checks
All inspection findings are recorded in both paper-based and digital log sheets, enabling real-time visibility into line performance and early detection of emerging quality trends.
100% Pre-Encapsulation Inspection
Every machine core (机芯) is fully inspected before it enters the encapsulation stage. Inspection includes appearance check, power-on and charging test, motor sound test, and brief aging test. Only cores that pass all checks are logged into the shelf management system (货架机芯管理表) and released to the encapsulation line. This step ensures that defective cores do not consume encapsulation capacity or result in finished goods that fail final inspection.
Waterproof and Aging Tests
After encapsulation, products undergo aging tests using喷油前的成品 as the test vehicle, following the TESDUR Finished Product Aging Inspection Record (塔斯狄成品老化检验记录表). Waterproof integrity is verified through visual inspection of the seamless overmolding line and random functional testing on sample units from each production batch.
Production Workflow: From Encapsulation to Finished Goods
TESDUR’s complete production workflow integrates quality checkpoints at every transition:
Encapsulation → Grinding/Trimming → Cleaning → Pre-Shipment Inspection → Packaging
Each transition point requires a documented quality handoff. Products that show any defect at any stage are immediately segregated, classified by defect type, and routed to the appropriate rework or scrap process. Critical defects result in disassembly and material recovery rather than repair.
Outcomes: Measuring the Impact
Since the implementation of the upgraded quality management system, TESDUR has observed measurable improvements in production consistency and customer-reported quality outcomes:
-
First-pass yield rate has improved significantly as defective cores are caught before encapsulation rather than after
-
Customer complaint rate related to product quality has declined notably among brand partners served by TESDUR’s OEM/ODM channel
-
Rework and scrap costs have been reduced through earlier defect detection and more precise in-process controls
Beyond quantifiable metrics, the quality upgrade has strengthened trust with existing brand partners and is increasingly cited as a key differentiator in new business conversations.
What This Means for Brand Partners
For brands sourcing from TESDUR, the quality management upgrade translates into tangible day-to-day benefits:
-
Consistent product quality across production batches, reducing the risk of downstream quality variation
-
Faster time-to-market through fewer production rework cycles and more predictable delivery schedules
-
Greater supply chain transparency through batch-level traceability from incoming materials to finished goods
-
Confidence for international compliance with FDA, CE, and RoHS requirements, supported by documented QC records at every stage
A Commitment to Continuous Improvement
TESDUR views quality management not as a one-time project but as an ongoing operational philosophy. The upgraded IOQ-PQC-OQC system will continue to evolve based on production data analysis, customer feedback, and emerging international quality standards.
TESDUR’s core values—Safety, Deep R&D, and Durability (S–D–UR)—are embedded in every inspection checklist, every production log, and every finished product that leaves the factory floor.
We are committed to being the manufacturing partner that global brands trust—not just for one order, but for the long term.
TESDUR Electronic Technology Co., Ltd. – Craftsmanship drives innovation, injecting limitless possibilities into global brands.
