A cosmetics brand sought a fun eyeshadow palette with a replaceable magnetic tray, secure hold, slim form, and retail-grade finish. Ezra delivered end-to-end injection molding: DFM and Moldflow validation, rapid prototyping, bridge tooling, precision molding, and assembly of lid, mirror, and tray. With magnet inserts, customizable surface finishes, and strict QA, EZRA ensured fast turnaround and scalable, cosmetic-grade production.
About the eyeshadow palette
The eyeshadow palette featured in this case is a customizable plastic packaging solution designed for beauty brands. It accommodates multiple pans, made from durable, eco-friendly ABS material with a sparkling white or glossy metal finish for a luxurious appearance.
Key components include a rigid base, hinged lid, integrated mirror, and inner compartments for eyeshadow pans. Innovations like magnetic and replaceable designs allow for refillable or modular setups, enhancing user convenience and sustainability.
EZRA Made’s ability to create brand-specific CAD designs, enabling startups to develop unique packaging without high upfront costs.
| Industry | Consumer Goods |
| Product | Fun Eyeshadow Palette — compact cosmetic case with replaceable magnetic tray (magnetic color palette that holds firmly and is changeable). |
| Main goals | Slim retail appearance, secure magnetic palette retention, interchangeable trays, retail-finish (matte / glossy / metallic), fast ramp from prototype → production. |
| Services Provided | DFM & Moldflow, injection molding (shell & tray), pad-print / UV coating, assembly (mirror + lid + tray), inspection & FAI. |
Ready to launch your own beauty product with custom, sustainable packaging?
Design brief: key customer requirements
- Replaceable tray: magnetic attachment so customers can swap palettes.
- Strong retention: tray must hold firmly during handling and transit.
- Cosmetic finishes: ability to deliver matte, glossy, metallic surfaces.
- Fast validation: produce production-like T1 samples and pilot runs before hardened tooling.
- Low assembly complexity: design for captured mirror and snap-fit inner frame where possible.
How we engineered the solution
DFM & Moldflow review
check wall thickness, draft, gate locations, cooling channels to avoid warpage and sink (free DFM offered).
Material selection
Shell: ABS/PC blend or PP for living-hinge designs;
Tray: POM/ABS for low friction and dimensional stability;
Magnets embedded or metal inserts for magnetic attraction;
Soft-touch or overmold options (TPE/TPU) if required. (EZRA supports a wide range of materials.)
Prototype stages
visual SLA prints → CNC functional prototypes → bridge tooling (aluminum) to produce production-like T1 parts for real-world fit/function testing. T1 capability: 2–3 weeks.
Assembly strategy
Either insert-capture magnets during molding/heat-staking or ultrasonic staking after molding; mirror capture in the lid to avoid glue steps where possible. Secondary ops such as pad printing, laser engraving, ultrasonic welding and heat staking are performed in-house.
Manufacturing flow
1) Plastic palette — injection molding
- Raw resin is injected into the mold; depending on shot size and tooling the shell can be formed in a single injection cycle (shell “appears” quickly — per your note, a visible part can form in ~1 sec of fill for small shot volumes). Molds run on presses sized to part volume (EZRA supports 50–3000+ ton range and tight tolerances).
2) Add color & surface finish
- We apply finishes and effects to the molded shell or tray: matte, glossy, metallic surfaces, pad/silk printing, UV coating, texture (SPI A1–D3, VDI 3400 available).
3) Assemble lid, mirror and inner frame (tray)
- Insert magnets or heat-stake magnet retainers into the tray or shell; assemble mirror and inner frame via captured-design or ultrasonic welding / heat staking to reduce manual gluing. Final assembly can be automated or hand-assembled per buyer requirements.
4) Inspection & QA
- FAI, CMM dimensional checks, visual SPI surface grading, hinge/latch and magnetic retention tests, packaged drop/transit tests, and CoC / RoHS / REACH documentation provided before shipment.
Validation & quality checkpoints
- Material verification (MTR/CoC) before run.
- Dimensional inspection: CMM for pan-seat tolerances and tray fit.
- Functional tests: magnetic pull/retention test, hinge/latch cycles, drop & transit.
- Appearance inspection: SPI surface grade, pad-print registration, scratch & abrasion tests.
Why Ezra Made for Your Project
- Full service, one partner — engineering + prototyping + tooling + finishing + assembly + QA under one roof reduces risk and lead time.
- Material & finishing depth — support for 100+ plastics and SPI surface standards (matte, glossy, metallic finishes available).
- Fast validation — bridge tooling and T1 samples let you test real production parts early.
- Production capacity & precision — machine press range and tight machining tolerances mean we can scale while holding critical cosmetic/fit tolerances.
WHAT WE ACHIEVED
A new cosmetics firm struggled to enter the personalized makeup palettes market. Long tool wait times, large minimum order quantities, and uneven surface finish quality caused delays and extra costs. Working with EZRA MADE, it cut production lead times by 70%, reduced costs with no-MOQ options, and enhanced item quality using eco-friendly ABS materials.
HOW WE GOT THERE
Our injection-molding experts reviewed CAD designs and analyzed requirements for glossy metal finishes and precise tolerances. There were issues with previous suppliers, like long tooling delays (up to 8 weeks) and large orders leading to overstock. Ezra Made used rapid prototyping, including DFM evaluations and T1 samples in 2-3 weeks, to improve the situation. For assembly, we refined hinge mechanisms, mirror integration, and magnetic closures for flawless functionality.
OUR SOLUTION
We streamlined multi-step manufacturing into an efficient end-to-end service, from design to delivery. The old way required separate vendors for molding, finishing, and assembly, driving up costs. With EZRA Made’s in-house injection molding, along with overmolding and insert techniques, the brand cut material use and achieved a 98.6% first-pass yield. Free proofing for first orders and customizable options like refillable pans greatly reduce setup time.
EZRA delivers end-to-end injection molding: DFM & Moldflow, rapid prototyping, bridge & production tooling, insert- and over-molding, secondary operations, assembly, and full QA/packaging. We support 100+ plastic materials, SPI surface grades, First Article Inspection (FAI) and CMM reports — plus free DFM and fast T1 samples.
