Frequently Asked Questions

New tooling is generally required for new molded products, significant shape changes, new support structures, or components that cannot be produced using existing molds or die-cut tooling.

Yes. FX can review substitute foams, top covers, adhesives, or support components when the original selection does not meet performance, appearance, cost, or manufacturing requirements. Recommendations consider the intended application, manufacturing feasibility, and production consistency. Any proposed substitute should be resampled against the agreed approval criteria.

Sample lead time depends on the development route and project complexity. Projects using existing tooling can often be completed within 3-7 working days, while new tooling or material validation projects typically require 2-4 weeks, depending on tooling, material availability, and approval cycles. The expected timeline is confirmed during project review.

The approval record should include the material grade, construction, dimensions, hardness or density target, approved appearance, top cover, logo application, packaging, tolerances, visual acceptance criteria, and market-specific requirements.

Each sample revision is documented with a version code, revision date, material specification, construction details, tooling status where applicable, and a clear description of changes from the previous sample. This helps all parties review development progress using the same reference.

Incoming materials are inspected before release to production. Depending on the material, inspections may include color, surface texture, thickness, hardness, density, weight, printing quality, logo appearance, and visible defects. Materials requiring performance verification are sampled and verified by the laboratory before production release, following the agreed test requirements for the project.

Laboratory verification depends on the project requirements and customer specifications. Performance materials such as EVA, supercritical foams, ETPU, PU, and other functional foam components are commonly verified before production. Typical evaluations include density, hardness, rebound resilience, compression set, shrinkage, tensile strength, tear strength, elongation, or other agreed validation items.

First-article approval is completed before full production begins. The approved sample is connected to an approved specification, material batch information, production site, and QC limits. Production inspections then include in-process checks, mold verification where applicable, material batch confirmation, and appearance and performance checks for consistency with the approved sample.

Yes. Batch verification follows the agreed customer or project quality plan. Testing frequency may vary depending on customer requirements, production volume, and risk level. Verification may include density, hardness, rebound resilience, compression set, tensile strength, tear strength, elongation, shrinkage, or other agreed validation items.

A useful lab report should identify the sample or batch, material specification, construction, production site, test date, method, result, tolerance, and approval status. It should also state whether the result supports approval, comparison, or defect investigation.

Third-party testing is added when a retailer, importer, buyer program, restricted-substance scope, neutral dispute review, or nominated reporting format requires external evidence beyond FX in-house checks.

Finished goods are inspected against the approved specification, visual standards, dimensions, packaging requirements, and agreed sampling plan before shipment. Products are released only after inspection records and required quality documents are verified.

Yes. Customers may arrange pre-shipment inspections with prior coordination. Customer representatives or appointed third-party inspection agencies may conduct inspections at the production site before shipment. FX conducts final inspection based on the AQL 2.5 sampling standard unless customer requirements specify otherwise. Relevant quality documents, inspection results, and product samples can be provided to support the inspection process.

Yes. Once tooling, material specifications, and production readiness are confirmed, most footwear components can be transferred between qualified FX manufacturing locations. Additional sampling or verification may be required when project specifications, materials, or customer requirements differ.

The transfer review covers tooling location, material availability, process route, schedule, packaging standard, production-site QC gates, and whether a new sample or lab report is required before release.

Change control applies when foam density, material grade, top cover, adhesive, mold, support part, logo method, packaging, production site, market requirement, or process setup changes after approval.

Pinholes, haze, wrinkles, exposed edges, edge damage, surface contamination, color migration, delamination, color mismatch, bonding marks, or logo issues are compared with the golden sample and agreed visual limits. The next action may be rework, resampling, tolerance clarification, or process adjustment.

The project team should decide whether to hold, rework, resample, or approve by exception using photos, measurements, lab results, and comparison with the approved sample. Non-conforming products are isolated until the disposition decision is completed.