How Are Vinyl Toys Made？
Definition of vinyl Toys::
Vinyl toys made from rotational molding materials are called rotational molding toys. This term classifies toys by production material. Rotational molding toys are a type of plastic toy, where rotational molding refers to the process, and plastic is the general category.
Features of Vinyl Toys:
They feel very comfortable to touch, smooth and slippery. Some are very soft, while others are hard, categorized as soft rotational molding and hard rotational molding. Additionally, they are hollow inside.
Origin and Current Status of Vinyl Toys:
Since the invention of the world's first rotational molding (ROTOCAST) machine in Germany in 1924 and the successful creation of the first toy, "Chocolate Bunny," rotational molding's unique shaping ability has brought endless visual novelty to the world. With the popularity of various iconic works, rotational molding has added vibrant colors to the traditional entertainment industry.
Rotational molding figurines come in a wide variety, from the early and popular Hong Kong street culture designs to the diverse categories seen today. Rotational molding has permeated every corner of entertainment life. Designed by internationally renowned designers, high-quality rotational molding figurines can even become art pieces. Regardless, they are dynamic and trendy art toys.
Due to the suitability of rotational molding vinyl toys for mass production, the market is flooded with a wide array of these vinyl toys, often competing on price and following a circulation model. In China, there are relatively few brands operating rotational molding vinyl toys. Notable brands include Cooloo Underwater World and Baby Paradise. However, due to the simplicity of the production process, there are many substandard vinyl toys in the market. Consumers should carefully identify quality when purchasing, such as checking for odors. High-quality rotational molding vinyl figurines should be odorless, while inferior ones may emit a pungent smell.
Classification of Vinyl Toys:
Based on their characteristics, vinyl toys can be categorized into four types:
1. By usage: keychain-type vinyl toys and water-friendly vinyl toys.
2. By properties: Solid vinyl toys and hollow vinyl toys.
3. By lighting capability: Light-emitting vinyl toys and non-light-emitting vinyl toys.
4. By shape: Aquatic vinyl toys and terrestrial vinyl toys.
Rotational Molding Basics:
Principle:
As the name implies, rotational molding involves injecting PVC liquid (gel) into a sealed mold cavity. The mold is heated by open flame (approximately 250°C–360°C, depending on product size and thickness) while rotating 360° to ensure the gel adheres to the inner walls of the mold and cures into shape.
Principle:
As the name implies, rotational molding involves injecting PVC liquid (gel) into a sealed mold cavity. The mold is heated by open flame (approximately 250°C–360°C, depending on product size and thickness) while rotating 360° to ensure the gel adheres to the inner walls of the mold and cures into shape.
Common Issues and Solutions in vinyl toy Process:
| Issue | Cause Analysis | Solution |
| Uncured Gel | Insufficient curing time or low furnace temperature | Extend curing time or increase furnace temperature |
| Bubbles | 1. Humid weather causing gel powder to absorb moisture. | Store gel powder in a dry environment. |
| 2. Deep recesses in mold structure. | 1. Modify mold design. 2. Use a centrifuge to remove bubbles before heating. 3. Adjust gel formulation. | |
| 3. Air bubbles in the gel mixture. | Vacuum the gel mixture properly. | |
| Water Marks | 1. Poor mold seal. | Repair mold. |
| 2. Gaps in mold inserts. | Repair or remake the mold. | |
| Yellowing | Overheating (excessive curing time or high furnace temperature). | Reset curing time and furnace temperature. |
| Excess Waste at Mold Cover | Mismatch between mold angle and cover angle. | Remake the mold. |
| Shiny Outer Surface | Worn mold cavity. | Sandblast the inner mold cavity. After sandblasting, coat the copper mold with a nickel layer to protect it from PVC corrosion. |
| Uneven Thickness | Uneven temperature distribution. | Wrap thick areas with tin foil or iron sheets to reduce heat exposure. |