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A new squishy shape needs a new mould only when an existing SKU cannot deliver the required geometry, size or surface detail. Compare the existing-SKU route with the original-shape route before paying a one-time tooling charge.
Tooling routes
| Route | Tooling need | Sample work | Typical MOQ |
|---|---|---|---|
| Existing SKU + branding | None | Artwork and pack proof | Ready-stock rule: 12 pieces/style |
| Adaptable existing shape | Possible rework [Factory confirmation] | One or more physical samples | [Factory confirmation] |
| Original shape | New production mould [Factory confirmation] | Prototype plus production-equivalent sample | [Factory confirmation] |
Mould cost is only one line in a new-shape project. Design preparation, prototype work, production tooling, colour/decoration samples and packaging proof each have a different deliverable.
When a new mould is necessary
- New silhouette, proportions or dimensions that an existing mould cannot produce.
- Undercuts, deep texture, logo relief or a new cavity layout.
- A different construction that changes how the skin, fill or foam is formed.
A logo label, printed bag, colour change or display box normally uses an existing product route and does not require a new toy mould.
What changes the tooling scope
| Driver | Effect on the project |
|---|---|
| Overall size and cavity count | More material, larger mould footprint and different production capacity. |
| Geometry | Simple rounded forms are easier to release; undercuts and thin projections need more tool work. |
| Surface detail | Fine texture, facial detail and logo relief require a production-ready surface definition. |
| Construction | Filled TPR, PU foam and silicone use different forming routes; the sample must represent the bulk process. |
| Revision count | Late changes to size, pose or surface can require rework or a new tool. |
Separate each one-time stage
- Feasibility and design review.
- Dimensioned drawing or 3D model.
- Prototype or first physical sample.
- Production mould.
- Decorated production-equivalent sample.
- Packaging proof and final approval.
Write each stage as included, separately priced, excluded or [Factory confirmation]. A prototype that proves the shape may use a different material from the production sample.
What the quotation should state
| Field | Record |
|---|---|
| Tool identity | Drawing revision, cavity count and intended product |
| Deliverables | Files, prototype, production mould and sample quantity |
| Revisions | Included rounds and the point after which rework is charged [Factory confirmation] |
| Ownership | Tool owner, storage, maintenance and release conditions |
| Schedule | Time from artwork approval to sample and bulk slot [Factory confirmation] |
Lock the design before tool approval
Use a revision number, annotated views, target dimensions and a list of accepted deviations. Record whether a change affects the mould, material, decoration or only the packaging. This prevents a low tooling line from hiding a later rework charge.
For the full custom-cost comparison, use How Much Do Custom Squishy Toys Cost?. Destination-market testing and labels apply to the finished variant.