Behind-the-scenes of bringing bandages from concept to cabinets

So...what actually went into getting these bandages from our concept to your cabinets? Well, the short answer is a box of donuts, an old-school lunchbox, a lot of trial & error, oh and uh... about $60,000!

Here's the transparent, behind-the-scenes story of what it really took to create this product & why we're so dang proud of it.

We talked to 7 different manufacturers before finding someone that we felt was actually interested in making a great product vs making a quick buck. We went through 4 moulds (that each cost about $6000) and eventually landed on this 3-piece design/shape. This was actually the easiest to assemble and the most structurally sound design.

During this time we also reached out to our community to ask for their thoughts. (If you've been a part of our community for awhile, you'll remember us reaching out about this).

Let's take a minute to speed up every step and iteration we took over the past 2 years to get to where we are today.


This is the final prototype we approved, which was our 4th iteration, and well over $20,000 in mould fees.
We really loved the nostalgic old-school lunch box tin look like what we saw as kids. So as an homage to our childhood and yours, we included the lockable latch. Also, no one wants to drop their tin and have 152 bandages explode all over the floor!
The inner trays were actually pretty tricky to nail down. We spent a good 16 months and 27 rounds of iterations on this alone. 
We landed on the current tray design to
- keep the bandages from shifting around in the tin
- make it easy to grab the bandage they wanted
- arrange the most used bandages on top for easy access
Adding the felt lining increased the grip for the bandages and actually helped add some rigidity to the trays. We also wanted to make sure the top tray was flush and fit nicely in the tin.
It actually looked like the picture on the left at one point...But thankfully we landed on the picture to the right...

Tin talk was really important for us to do our research on making a medically accurate bandage. Early on in the process we connected with Dr Robin, a top pediatric dermatologist in Seattle. It was like getting a masterclass in wound care every time we talked.

You'll see her when you open up the bandage tin with some helpful tips. We actually decided to decrease the size of gauze pads so that the bandage would form a perfect seal around the wound vs letting air flow in and out. Because apparently when it comes to wound healing, air flow isn't the best and moisture is key! You can actually catch her full interview at the link below to hear her answers to top pediatric skincare & wound care questions!

One of our core ethos is to test and certify every product we make so we performed 2 different tests on our bandages.
Test #1 (Report #SFT23052745250E) was for latex. I learned that while most bandage adhesives have latex, the adhesive that seals the clear wrapper bandage does have latex. Our bandages as well as the clear wrapper were fully tested and zero latex was found. 
Test #2 (Report #EFSH23070371-CG-01) was for inks. There were 4 main things we tested for in the colored inks. Heavy metals, lead, phthalates, and cadmium.All results came back with zero detection. 
The cherry on top of our design was inspired by that first thing we talked about.. when our kids just want a little bandage or sticker to make them feel better. So we designed a bonus sticker sheet full of empowering affirmations to use for these "emotional ouchies".

These bandages, also known as "Cupkin Stripes" were hands down the most challenging product I have ever created. Each component impacted the others, which is why the mould needed adjusted so many times. The total investment for moulds, material, engineering, and testing is north of $60,000.

But man...we couldn't be more proud of how it turned out.

And the hardest part of it all? Getting my wife to stop calling them "Bandaids".

Our plan moving forward is to launch a bunch of cute new designs (which are already well on their way) and some refill packs to keep your tins stocked up.

Until next time,
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