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How To Make Vinyl Toy?

What is a Vinyl Toy?

A Soft Vinyl Toy, commonly referred to as a Rotocast or Rotational Casting toy, is a type of collectible or designer figure known for its distinctive manufacturing process and unique tactile qualities.

Here are its key characteristics:

· Material & Feel: It is made primarily from soft, flexible Polyvinyl Chloride (PVC). This gives the toy a characteristic hollow, slightly yielding, and pleasant hand-feel, distinct from hard plastic or resin figures.
· Core Process – Rotational Casting: The defining production method is Rotational Casting (Rotocasting). Liquid PVC is injected into a sealed, hollow mold. The mold is then heated and rotated simultaneously in multiple axes. Through centrifugal force and gravity, the liquid PVC evenly coats the inner walls of the mold, creating a uniform, hollow shell as it cures. This allows for the creation of complex, seamless shapes.
· Key Features:
· Hollow & Lightweight: The interior is mostly empty, making the figures relatively light despite their often substantial size.
· Seamless Construction: The rotational process typically results in a one-piece main body without a visible parting line, offering a clean aesthetic.
· Articulation (Commonly): While some are static, many feature articulation points (like swivel joints at the head, arms, and legs) achieved by assembling multiple rotocast parts.
· Artistic Canvas: The smooth, matte vinyl surface is ideal for intricate, hand-painted details, making each piece a unique artistic expression. The process is prized for its handcrafted feel compared to mass-injection molding.
· Common Use: This technique is iconic in the world of designer toys, art toys, and collectibles. It is the preferred method for producing limited-edition or high-end figures from artists and brands (e.g., early Medicom Toy BE@RBRICKs, figures by artists like James Jarvis, or classic character toys).

In summary, a Soft Vinyl Toy is a hollow, collectible figure made by rotating liquid PVC inside a heated mold. It is valued for its soft texture, seamless form, and suitability for detailed hand-painting, making it a staple in art and designer toy culture.

Rotocasting (Vinyl Toy) Process Flow

Step 1: Mold Preparation & Material Injection
Evenly apply a mold release agent to the mold cavity. Inject a pre-measured amount of liquid PVC into the mold, precisely controlling the volume to ensure complete filling without overflow.

Step 2: Mold Closing & Sealing
Securely close and lock the mold to create a fully sealed environment. This prevents material leakage during the subsequent heating and rotation stages.

Step 3: Rotational Heating & Curing
Place the sealed mold into a heating oven. Initiate multi-axial rotation while heating to a set temperature (typically 160-200°C). This process lasts 3-5 minutes, allowing the PVC to evenly distribute and cure against the inner mold walls, forming a hollow shell.

Step 4: Cooling & Setting
Remove the mold from the oven and promptly submerge it in a cooling water tank for approximately 3-5 seconds (water quenching). Remove immediately afterwards to prevent over-cooling, which can complicate demolding.

Step 5: Demolding
Open the mold and introduce a small amount of compressed air into the cavities to aid part release. Carefully extract the formed soft vinyl components using specialized tools or clamps.

Step 6: Post-Processing & Inspection
Trim away sprues and parting line flash (excess material). Conduct a preliminary quality check on the blank (unpainted) rotocast parts to identify any major flaws before they proceed to painting and decoration.

Custom Vinyl Toys: Cost & Lead Time

Leverage our integrated toy manufacturing ecosystem in China for your limited-edition designer art toys. We specialize in small-batch production, accepting custom vinyl figure orders with a minimum order quantity (MOQ) of only 100 pieces—significantly lower than the industry typical MOQ of 500-1000 pieces.

Cost Structure
The total customization cost is calculated based on your project’s specific requirements and includes:

· Prototyping & Sampling
· Mold Making
· Mass Production
· Packaging

Key factors influencing the final price are: quantity, figure size, quality specifications, and design complexity. Higher order quantities benefit from a lower unit cost. Contact us with your design for a detailed, no-obligation quote.

 


Submit Your Design for Quote

Production Timeline
The standard lead time from design to delivery is 25 to 50 days, covering the complete process:

1. Prototype Development
2. Mold Fabrication
3. Mass Production (Rotocasting, Painting, Assembly)
4. Quality Control
5. Final Packaging

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