RESEARCH AND DEVELOPMENT
R&D
Comprehensive Solutions for Foam Material and Product Design, R&D, Testing, and Production
Our founder, Mr. Philip Chang, has over 45 years of expertise in composite and foam materials.
At Phinomenal, we cultivated a dedicated team with extensive professional experience in foam production, research and development, business operations, market development, and marketing strategies.Our goal is to provide clients with deep insights into market trends and assist them in transforming their initial concepts and development plans into tangible products. Through our professional JDM (Joint Development/Design Manufacturing) services facilitate close collaboration with clients to streamline product design and innovation as well as material development.. This ensures that innovative ideas are effectively translated into manufacturable and market-ready solutions.
Beyond foam and composite materials, we specialize in custom plastic injection molding, offering comprehensive plastic injection product development solutions. Our expertise extends to custom plastic molding, injection mold creation, and custom plastic parts manufacturing, ensuring high-quality, market-ready solutions. With deep expertise in Design for Manufacturability and Assembly (DFMA), we refine product designs to minimize production costs, improve manufacturability, and ensure smooth, high-efficiency manufacturing processes.
Beyond foam and composite materials, we specialize in custom plastic injection molding, offering comprehensive plastic injection product development solutions. Our expertise extends to custom plastic molding, injection mold creation, and custom plastic parts manufacturing, ensuring high-quality, market-ready solutions. With deep expertise in Design for Manufacturability and Assembly (DFMA), we refine product designs to minimize production costs, improve manufacturability, and ensure smooth, high-efficiency manufacturing processes.
We have invested in an EVA foam factory in Changhua, Taiwan, with 35 years of experience, establishing a robust R&D and export team. This investment allows us to fully consider our client’s design philosophies thoroughly during product development while working closely with the factory team to evaluate manufacturing feasibility and improve production efficiency. Phionmenal is a prototype manufacturer specializing in product design and development. With extensive expertise, we provide Design for Manufacturability (DFM) services that balance design and manufacturability. This enhances our Original Design/Development Manufacturer (ODM service) and Original Equipment Manufacturer (OEM service) capabilities, enabling us to quickly adapt to market shifts and accelerate product time-to-market.
OUR ADVANTAGES
One-Stop Service
Seamless integration from product development to final delivery, saving you time and effort.
Market-Driven Approach
Keeping pace with market trends to ensure your products align with industry needs.
Expert Team
Extensive industry knowledge and experience ensure the success of every project.
Flexible Collaboration
Customizable solutions tailored to enhance product competitiveness.
Dual Verification System Ensuring Excellence in Innovative R&D
Phinomenal specializes in the research and development of composite foam materials, focusing on market trends and innovative product design solutions to enhance product uniqueness. Our extensive knowledge encompasses various foam technologies, such as traditional EVA foaming, injection molding, small-scale mold foaming (compression molding), pouring techniques, and extrusion processes. These capabilities enable us to cater to diverse material and product requirements while maximizing end-product performance.
Throughout the development process, we conduct in-house research and collaborate closely with clients to create a wide range of composite foam materials. Our developments include protective foam materials, polyurethane foam (PU foam), ethylene-vinyl acetate foam (EVA foam), eco-friendly materials, recycled foam, and micro-foamed materials. With our extensive expertise, we engage in deep prototype product development, ensuring that material properties and product safety meet the highest standards.
To guarantee material performance and product safety, we conduct various in-house physical tests, including hardness, density, resilience, shrinkage, tensile strength, tear strength, elongation, compression deflection, compression set, and water absorption.
To guarantee material performance and product safety, we conduct various in-house physical tests, including hardness, density, resilience, shrinkage, tensile strength, tear strength, elongation, compression deflection, compression set, and water absorption.
We also work with third-party testing agencies for certifications such as EN1621-1 limb joint impact tests, EN1621-2 back protector impact tests, and EN13158 equestrian safety impact tests.
Our laboratory facilities allow for preliminary physical testing, significantly shortening development cycles and impoving efficiency. If you're interested in our expertise or potential collaboration, please feel free to contact us. We look forward to co-developing exceptional products with you!
How to Manufacture a Prototype Product:
From Concept to Production
01
Design Phase
We begin by thoroughly understanding the client's concept or design sketches, and conducting a comprehensive analysis of the product's functionality, appearance, specifications, and intended use. Market research is performed to assess feasibility, and we provide expert recommendations to help clients refine their product direction and reach a consensus on prototype product development.
02
Material Selection
We offer expert material manufacturing product design insights to recommend the most suitable materials based on product characteristics and intended use, ensuring optimal performance and manufacturability.
03
Prototype Production
We utilize advanced technologies such as 3D printing, CNC machining, and handcrafted techniques to create prototype development samples. This process helps visualize the product and identify potential issues before mold production begins.
04
Testing and Evaluation
Comprehensive functionality tests and user evaluations are conducted to gather and ensure the product meets market demands. Each round of testing and evaluation includes detailed data analysis to meet expected standards.
05
Mold Design
After confirming the test results, we proceed with mold-making. This involves creating detailed mold drawings based on the final design and specifications, ensuring accuracy. We maintain close communication with clients to ensure that the mold design aligns with expectations before production begins.
06
Mass Production & Quality Assurance
During mass production, we enforce rigorous quality control and monitoring at every stage to ensure consistency between prototypes and final products. Our strict standards guarantee that every product meets high-quality benchmarks before reaching the market, emphasizing our commitment to prototype development services.
07
Packaging and Shipping
We offer flexible logistics solutions tailored to client needs, collaborating with logistics partners to ensure products are securely packaged and shipped on time. We guarantee that every product arrives safely and provide ongoing after-sales support to address any potential issues.