The roadblock? The Tooling Cost (Mold Fees).

In the world of High-Frequency (HF) welding and TPU manufacturing, custom molds are expensive. For a startup or a brand testing a new concept, investing thousands of dollars in molds just to see a first physical sample is a massive risk.

After 20 years of manufacturing high-end soft coolers for European and American markets, we have seen this struggle time and time again. But we also know a secret solution.

Here is how you can develop your custom cooler bag prototype at a fraction of the cost—and speed up your time-to-market—by leveraging our “Factory Archive.”

The “Hidden” Cost of Innovation

Unlike sewing, where you can cut fabric and stitch it together relatively cheaply, manufacturing waterproof TPU products requires precision technology. We use High-Frequency Welding to fuse materials together.

To do this, we need specific molds (dies) for every shape and curve. If you want a personalized cooler design that is 100% unique in its dimensions, we must machine new metal molds. This adds significant time and cost.

But there is a smarter way.

The Solution: Leveraging Our 20-Year “Mold Library”

Over the last two decades, our factory has produced thousands of different waterproof bags. We haven’t just accumulated experience; we have accumulated a physical library of thousands of molds.

These molds cover almost every standard shape, volume, and dimension you can imagine.

Here is our proposal to you: Before you commit to opening a brand new mold for your custom cooler bag, let us see if we already have a “twin” in our warehouse.

How to Create a Personalized Cooler Without New Molds

Instead of starting from zero, we recommend this low-risk workflow for your next prototype:

1. Browse and Match

Visit our website or send us your concept sketch. Look for a model in our catalog that resembles your desired shape.

2. The Compatibility Check

Contact our engineering team. Ask us: “Do you have an existing mold that is close to these dimensions?”

3. The “Low-Cost” Prototype

We can use that existing mold to create your first physical sample. Even though the shape is standard, we can still create a fully custom cooler bag by changing the materials, colors, webbing, handles, zippers, and logo placement. The core shape (the “body”) will simply be based on our stock mold.

4. Validation

You receive a fully functional, high-quality TPU sample. You can test if your personalized cooler design meets your insulation and leak-proof standards.

• If it works: Great! You can go to mass production using our existing mold, saving you 100% of the tooling fees.
• If it needs changes: You now have a physical reference to modify for your final mold.

Why This Strategy Wins for Your Brand

Beyond saving money, this approach solves three major problems for international buyers:

1. Drastically Reduced Lead Time Opening a new mold takes weeks. Pulling an existing mold off our shelf takes minutes. We can often finish a sample in 7–10 days.

2. Smoother Cross-Border Communication Communicating a complex 3D shape via email can be difficult. Using a reference model ensures the first sample is much closer to your vision.

3. Risk Mitigation We want your custom cooler bag project to succeed. By lowering the entry barrier, we allow you to test your market without a heavy upfront investment.

Let’s Raid Our Archive for You

Your design is unique, but the geometry required to build it might already exist on our factory floor.

Don’t let the fear of prototype costs kill your great idea. Browse our product catalog today or send us your rough sketch. Let us help you launch your personalized cooler line using our 20-year archive.