Custom Vinyl Toys: How They Are Manufactured

For large-scale toy collection production, PVC and ABS are ideal choices, while PU resin and polymer resin are better suited for small-batch artist/designer toys. The appearance, strength, and size of the product determine the characteristics of the chosen materials. Different materials exhibit different properties - some are thermoplastic, others are cold resin, impacting production time, scale, and costs (molds, labor).

PVC and vinyl are the most commonly used materials in the toy industry. The majority of toys at art toy exhibitions are made from PVC, vinyl, or a combination of both. PVC is durable and often found in action figures, dolls, and toy sets. Vinyl, on the other hand, is softer and suits bath ducks and designer toys better.

PVC toys stand out due to their lightweight, insulation, thermal conductivity, moisture resistance, fire resistance, acid and alkali resistance, and corrosion resistance. Production techniques involve compression, mixing, stretching, granulating, extrusion, or injection molding, making it easy to process and assemble later on.

In summary, apart from one-time creation, the mass production process for designer toys typically undergoes several stages:

Design → Prototyping → Mold Making → Molding → Coloring → Assembly

Prototype Creation: Usually, a 3D model is created based on toy design sketches provided by artists or toy designers. Then, using 3D printing technology, a prototype sample is produced from that 3D model. Subsequently, manual coloring is applied to create specific samples. This process may involve various materials and techniques to confirm the product's appearance and dimensions.

PVC Toy Mold Making: The process involves designing the mold structure based on the sample or 3D model, considering factors such as output, product structure, and details. Precision machinery or manual methods are then used to make the mold, typically using metals such as steel or copper. Mold-making is a crucial step affecting product quality and production efficiency. Once completed, the mold undergoes testing to ensure its functionality and stability, with adjustments made if necessary to meet product requirements.

After mold completion, mass production can begin. The quality and precision of the mold significantly impact the molded product's quality. These steps require highly specialized skills, equipment, and strict quality control measures to guarantee toy production quality.

Injection Molding for PVC/ABS Toys: Injection molding technology is widely used in everyday plastic products like computers, phones, cups, and speakers. In the toy industry, it is used for high-precision assembly of toys such as art toys, designer toys, and blind box collectibles.

The process involves melting solid plastic pellets (PVC, ABS, etc.) at specific melting points. The molten plastic is injected into molds by machines, cooled via channels, forming products mirroring the mold cavity.

The entire injection molding process can be automated, enabling high-speed, efficient production, ideal for large volumes, ensuring accuracy in complex shapes.

The drawbacks of injection molding are seam lines and gate marks, which are inevitable at mold connection points. Premium art collectible toys often undergo careful polishing.

Coloring PVC Toys: Color schemes for PVC toys are planned during mold-making to simplify coloring. Different colored toy parts are often separately batch-colored, using commonly spray painting, pad printing, or special techniques like water decals or advanced electroplating, if necessary, manual coloring is also viable.

Final Assembly and Packaging:Toy part assembly is typically done using environmentally friendly adhesives specific to the toy industry. Some articulating figures are designed with snap-fit structures during the mold design phase for easier assembly. Replaceable components often use magnetic structures. In packaging, most high-end art toys use foam inlays combined with gift boxes. Higher-tier options may include wooden boxes, PVC boxes, or windowed boxes.