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Case Study
Helping a Japanese Brand Test Small-Batch Products
At the 2025 Tokyo International Gift Show, we met Japanese customer Sanae Sano, who mainly sold products through Amazon Japan and Rakuten. The customer wanted to test foldable kids mattresses, play mats, and pillows in small quantities before expanding the product line.
Our Solution
Product Solution
1
Using Existing Materials for Flexible Development
Because the customer was still testing the market, the first order quantity for each product was only around 150 pieces. To support small-batch production more efficiently, we prioritized existing stock cotton fabrics and used the same quilted cotton material across multiple product categories.
2
Building a Breathable Foldable Mattress Structure
For the foldable kids mattress, we used a 4cm thick 65D POE air fiber core with dual firmness on both sides. The opposite fabric side combined AD2D-7F spacer mesh material to improve airflow and overall breathability during sleep and floor use.
3
Developing Different Internal Structures by Product Type
The game mat used 800gsm firm polyester padding with a 2.5cm thick structure to improve floor support performance. Meanwhile, the mattress and pillow products maintained softer and more breathable structures suitable for children’s daily sleeping and resting environments.
4
Optimizing Packaging for E-Commerce Sales
To help the customer directly handle Amazon and Rakuten fulfillment after receiving products, we used reinforced kraft mailer box packaging. This reduced additional repacking work while improving transportation protection and warehouse storage efficiency.
Results
What We Achieved
The customer has already placed repeat orders four times and continues expanding the product collection for the Japanese maternity and children’s market.
