From Master to Multiples: How We Prototype, Test, and Scale Custom Candles

Custom molded candles · sculptural soy candles · bespoke silicone molds — made in Croatia, shipped worldwide.

Turning a one-off sculpture into a repeatable, retail-ready candle is part art, part industrial choreography. Here’s exactly how we go from a single master to dozens or hundreds of flawless casts—with consistent finish, color, and burn.

TL;DR — Our Scale-Up Blueprint

  1. Master: high-res print + hand finishing (the truth source).

  2. Prototype loop: tune wax–wick–geometry with structured burn tests.

  3. Tooling: build platinum-cure silicone molds + rigid mother-molds.

  4. Pilot: 10–20 units to lock cycle times and QC gates.

  5. Scale: parallel molds, takt time, cooling cadence, packaging line.

  6. QC: AQL sampling, defect taxonomy, traceability, care-card standards.

1) The Master: Your Geometry’s Gold Standard

  • Master creation: 3D print (high layer resolution) → sanding, sealing, edge crisping → optional micro-texture (matte leather grain, stone, etc.).

  • Why it matters: Silicone copies exactly what it sees. A perfect master yields perfect molds—and cleaner seams later.

Deliverables: Master model, finish spec, seam/parting map.

2) Prototyping: Design Of Experiments (DoE) For The Burn

We cast small test batches and change one variable at a time:

  • Wax system: soy-forward vs. beeswax-forward; hardness tuned to geometry.

  • Wick: size/series and micro-offsets for asymmetrical forms.

  • Pour window: temp band for finish (matte/satin) and bubble control.

  • Color load: pigment % affects heat absorption; we compensate via wick/geometry.

We log: flame height, melt-pool diameter/depth, time to photogenic window, soot risk, tunneling, shell behavior.

Outcome: A locked production recipe (wax code, wick code, temps, timings).

3) Tooling Up: Molds That Make Multiples

  • Material: Platinum-cure silicone (low shrink, high tear strength).

  • Architecture: Multi-part with registration keys, funnel, and micro-vents for tips/handles/ears.

  • Mother-mold: Rigid outer shell keeps geometry true and seams laser-straight.

  • Labeling: Each mold set gets a lot code for traceability.

Result: Fast demolding, crisp details, minimal finishing.

4) Pilot Run: Proof Before Scale

  • Batch size: 10–20 units.

  • We measure: pour → cool → demold → trim → finish → pack cycle times, scrap rate, and operator notes.

  • Adjustments: add mold sets, tweak cooling racks, refine trimming SOP.

Go/No-Go: When takt time and quality stabilize, we green-light volume.

5) Scaling Production: Throughput Without Rush

Throughput math (example):

  • Cooling-limited medium piece → ~2 casts/mold/day

  • With 4 identical molds → ≈ 8 units/day

  • Need 160 units → ≈ 20 production days (or halve with 8 molds)

Levers to scale safely:

  • Increase mold count (not pour temp).

  • Stagger pours to respect cool-down windows.

  • Parallel finishing/pack stations.

  • Color batching (one color/day reduces changeover and QC noise).

6) Quality Control: What We Check (And How Often)

QC Gate Check Method Frequency
Post-demold Weight, dimensions, seam alignment Calipers, jig Every unit
Surface Bubbles, sink dimples, frosting Raking light Every unit
Color ΔE vs. target swatch Visual + daylight box 1 per 10
Burn Flame, melt-pool, soot 2–3h test 1 per 30 (AQL)
Packaging Cleanliness, label, care card Visual Every unit

Defect taxonomy & actions:

  • Critical (structural cracks) → scrap.

  • Major (seam misalignment) → rework/trim.

  • Minor (micro scuff) → polish/approve.

Every tray carries lot codes (wax, wick, pigment, operator, date) for traceability.

7) Color, Scent, and Finish Control

  • Pigment dispersion: pre-mix in a small wax aliquot for streak-free color.

  • Dark tones: absorb more heat → wick down or adjust geometry.

  • Fragrance: within supplier % limits to protect burn and color stability.

  • Finish: matte vs. satin = different pour/cool bands; documented in the recipe.

8) Packaging That Protects (And Photographs)

  • Options: minimal kraft with belly band, or rigid gift box with insert.

  • Transit safety: corner protection, movement-free fit, melt-safe care card.

  • Branding: embossed sticker/foil sleeve; QR to story or care page.

9) Documentation You Receive

  • Spec sheet: wax/wick codes, pour temp band, demold time, cure time, finish SOP.

  • Tooling dossier: mold count, part map, venting scheme, maintenance tips.

  • QC summary: pilot stats, AQL plan, approved tolerances.

  • Media pack (optional): styled photos for PR/e-commerce.

10) Sustainability Notes

  • Soy/beeswax options, EU-sourced materials where possible, recyclable packaging.

  • Small-batch precision minimizes scrap; defect data loops back into continuous improvement.

IP & Approvals

If we reproduce a product shape or logo, we’ll need written permission from the rights holder. We can advise on feasibility and tasteful brand placement (deboss/emboss).

Ready To Go From One To One-Hundred?

Send your brief via Contact us:

  • Size (L×W×H) & reference photos or STL/OBJ

  • Quantity & deadline

  • Wax (soy/beeswax/blend), color, optional scent

  • Packaging preference

We’ll return a throughput plan, timeline, and itemized quote (including options to accelerate with extra molds).

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