Vinyl Dip Molding

Vinyl dip molding evolved from the art of candle making. Over the years, technology provided the means to create molded vinyl products without the expense and overhead compared to plastic injection molding. The vinyl dip molding process is incredibly simple in it's basic form, yet extremely complicated and precise in execution. The process begins by first creating a mold for the part which is to be manufactured. The mold is made of metal and the number of molds that will fit in a single dip molding step is determined by it's size. The mold is then heated to a precise temperature prior to dipping into the liquid vinyl material. The liquid vinyl, called plastisol, is a petroleum based product which is carefully formulated to produce specific hardness (durometer), color and texture characteristics. The plastisol is kept cool and the mold is dipped into the material just as a candle is dipped into wax. The heat of the mold draws the plastisol to itself. The length, speed and duration of the dip is carefully controlled to ensure uniform wall thickness of the vinyl parts. The molds are then carried through an oven, set to a precise temperature which "cures" the plastisol, creating a hardened vinyl product. The hardness of the final vinyl product covers a huge range. At the end of the vinyl dip molding process, the pieces are cooled and removed from the molds, generally with the assistance of compressed air so as not to mar or otherwise damage the still warm vinyl pieces. It's at this point then, that the products may be put through secondary processes such as printing, cutting or slicing depending on what the final product is designed to do.

Vinyl dip molded parts can also be double, or in some cased, triple dipped to create multi-layered products such as "can coolers", tool handles and more. The practical applications for dip molded vinyl products is virtually unlimited. From use in the food service, appliances, automotive industry, commercial and industrial applications, the process is limited only by imagination. In the end, dip molded vinyl products are inexpensive to produce and an economical alternative to other methods of plastic product production.

Benefits of Dip Molded Caps and Plugs:

• Caps of varying lengths can be made with no tooling charge.
• Vinyl material stretches to fit odd shapes and easily conforms to beaded or flared tubes.
• Vinyl material will not crack or split like Low Density Polyethylene.
• Vinyl material does not shred when capping or plugging threaded items.

Benefits of Custom Dip Molding

• Low tooling costs...typically a fraction of injection molding.
• Quick and inexpensive prototypes.
• Short lead-times on custom tooling...weeks versus months.
• Innovative materials and textures.
• More vibrant colors can be achieved with vinyl.
• No internal stress molded into parts.
• Large parts can be made without significant tooling investment.
• Multi-Dipping capabilities allow us to design products with two colors or materials on one part - typically used for making products with durable inside liners and more consumer friendly exteriors.