Starpery Weight Reduction Tech 4.0
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The Development Of Weight Reduction Tech
Before Starpery successfully launched the weight reduction technology, the weight of silicone dolls has always been a major pain point in the doll industry and a major problem that troubled lots of doll users. Most of BBW/Chubby enthusiasts were deterred by the weight and were forced to choose some light or distorted-proportion dolls. Starpery has focused on this century-old problem since the establishment of the brand. In 2021, after spending countless days and nights R&D, we finally launched the weight reduction 3.0 technology to bring good news to fans. As the first brand in the sex doll industry to realize TPE and silicone doll weight reduction technology, Starpery has achieved good results in terms of weight and softness. However, when the weight reduction technology was applied to production, we found that it was difficult to standardize the weight reduction, resulting in some dolls being a bit stiff or heavy. The weight loss data changes frequently....
After further testing and research, we found:
---If we choose the softer W.R. foam core, the much heavier silicone/TPE materials (weighs up to 25kg) will severely squeeze the foam core when pouring, which caused the foam core to harden and made the weight loss poorer…
---If we choose the harder W.R. foam core, the doll will be much lighter but with a poorer softness…
How to better control and balance this two aspects? This contradiction has always haunted W.R. 3.0…
Therefore, Starpery determined to find a better way to resolve this contradiction! Based on the above analysis, we found that it is necessary to reduce the extrusion of the TPE/silicone material on the W.R. inner core during the pouring production. BUT! How can this be achieved? At the beginning of 2022, Starpery W.R. Team was formed, independent of our factory, we started R&D testing in a small room.
Our team tried various methods...
Method 1: Keep the doll mold lying flat then pour the materials to reduce the gravity effects of TPE/silicone on the W.R. inner core…
Method 2: Use the spindle frame to fix the doll mold for rotary pouring, then injected the foam inside the mold… (Since the picture was lost, we found a similar picture of the spindle frame on the Internet, as shown below)
Method 3: Try the drip irrigation method to pour the material into the mold…
Until the Nth method, we still didn't find a better, more effective and more standardized method to achieve it. Then our team fell into suspicion and even thought that achieving effective weight loss and the great softness was an irreconcilable contradiction in itself.
After taking such lots of time in R&D, failed lots of times, team members are a bit discouraged and don't know how to move forward... Persuaded by our company's leaders, W.R. team regain confidence and find more ways! team came up with an idea: How about separating the mold and pouring silicone/TPE below the body first, then pour the rest before they solidified.
Therefore, we selected 172 body for the First Silicone mold redesign and remolding. After the mold is done, we started production and got a softer & lighter doll, but there added more mold lines, also some parts of the body are prone to lack of material, as pictures shown:
When we saw the light at the end of tunnel, more problems arose... Have taken more than half a year, it seems that we returned back to the original point... Then, our team summarized their work in the past six months and got some useful tips:
- The non-woven fabrics we used all the way will increase the hardness of the foam core, we need to find a way to cancel it, and make the foam core directly attach to the silicone.
- Use the drip irrigation method to pour the material into the mold, although it is slow, it helps a lot to slow down the compression of the material on the inner core.
- The material pouring method changes, adopt the horizontal mold pouring first, then vertical pouring.
At the beginning of 2023, our W.R. team started to use the new method. By improving the foam core mold, reduced the errors between the skeleton and the inner core, and the situations of uneven skin, body lacking of material. Meanwhile, control the thickness of the doll's skin by controlling the thickness of the foam core. The doll skeleton + foam core + doll mold are integrated into one piece! Through those improvements, we finally made a more satisfactory 172 body. This one is about 5.3kg lighter than the W.R. 3.0 body and with a more realistic softness.
Although we got the relatively satisfactory results in the laboratory, there is still a big difference in the mass production. In fact, the defective rate has always been a problem for super weight reduction. Moreover, we wanted to minimize the mold line, so we modified the mold again. Restore the mold to the original design but add openings in the hand and feet areas, which is used to fix the skeleton and to make the hard hand and feet. Further reducing the thickness of the foam core, and allow a certain amount of silicone material pressure on it to achieve a better result. In the pouring, we purchased a new machine to assist in standardizing production.
In July 2023, we tested 172 and 151 two dolls. With W.R.4.0, this two dolls are much lighter:
---172 body weight can be reduced from 35+kg (W.R. 3.0) to 29kg,
---151 body's weight can be reduced from 25kg (W.R. 3.0) to about 19kg.
Also, their softness are so great. The softness of the entire silicone doll is solid soft, not only soft on the skin surface, but soft overall, even softer than TPE.
In October 2023, we completed multiple pouring tests of these 2 dolls, basically confirmed the effect. Then we started the toughness tests of the dolls and so on. The development of W.R. 4.0 also let us believe that we can solve the contradiction between softness and weight. But there still need more time to continue optimizing and improving.
In April 2024, Starpery officially launched out the W.R.4.0 and apply it into mass production, so far, we have received lots of support and positive feedbacks from our customers. We know for sure that weight reduction tech still needs to be improved, and we have officially started the research and development of the weight reduction 5.0 era.
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Deep Revelation Of Weight Reduction 4.0 Tech --- Why Starpery silicone doll is light and soft?
First of all, we need to solve the softness problem of inner foam core. Use the self-skinning of the inner core to form a protective layer to prevent silicone liquid material excessive penetration and hardening the inner core surface. Welcome to look at the W.R. 4.0 inner foam core video: https://drive.google.com/file/d/10BQXkBqbibkrO3aToRtrcrWgtTq9TMnw/view?usp=sharing In the video, we can easily see that the W.R. 4.0 foam core is very soft and feels very close to a real person's fat layer. So far, we have solved the problem of the softness of the liner, but we have not solved the problem of weight. During the pouring process, the traditional foam core will be severely squeezed by the silicone liquid, and the foam core size reduced and the skin surface becomes harder, resulting in a significant reduction in the weight reduction effect. In order to solve this problem, Starpery has developed two new technologies:
The first one is dual-mold foaming technology: by combining the inner core mold and the body mold to simultaneously bind the skeleton, so that the shape of the foam liner can be more accurately controlled. Then the thickness of the foam core mold is used to control the skin thickness of the silicone doll, so as to achieve more precise control of the skin thickness of the silicone layer.
The second is the pre-flow channel technology, which pre-grooves the foam core and guides the silicone material to flow slowly from the top, thus perfectly avoiding the silicone material from squeezing the soft core(As shown in the figure below).
Then, by slowly pouring the material through the machine, we can perfectly solve the problem of weight and softness. We also named this technology as weight reduction 4.0 technology (W.R. 4.0). The invention of this tech can completely change the production methods and processes of the whole silicone doll industry. Then Silicone dolls start the era of W.R. 4.0 era.
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W.R.4.0 Silicone Doll VS W.R. 3.0 Silicone Doll
To better display W.R. 4.0 silicone doll's softness and lightness, here Starpery has taken a comparison video for you to have a look:
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W.R.4.0 Silicone Doll
Starpery now offers W.R. 4.0 in most of our popular models, including:
85cm G cup Torso
148cm J cup Doll
151cm B cup Doll
156cm E cup Doll
159cm E cup Doll
161cm H cup Doll
163cm G cup Doll
165cm G cup Doll
168cm H cup Doll
169cm C cup Doll
171cm A cup Doll
171cm D cup Doll
172cm F cup Doll
173cm G cup Doll
174cm C cup Doll
176cm F cup Doll
Please check those dolls latest measurements data:
We will release more models in November, and if you have any questions, please feel free to contact us via email: info@starpery.com