what is PVC?

First let's learn what is called PVC, PVC full name polyvinyl chloride (Polyvinyl chloride), is the world's third largest production of synthetic polymer plastics (after polyethylene and polypropylene). According to the different scope of application, PVC can be divided into: general-purpose PVC resin, high polymerisation PVC resin, cross-linked PVC resin. The general plastic art toy industry uses general-purpose PVC resin, PVC processing methods are also varied, can be pressed, extruded, injected, coated, etc. PVC figurines are generally made using injection molding machines with various molds, PVC is a material that can be adjusted to the softness of the toy through the addition of the amount of plasticizer, PVC figurines are easy to colour and not easy to deteriorate, so PVC is very useful for customize collectible toy figurines.

PVC figurines are also called PVC figures or PVC Models. So how do plastic toy factories make PVC figurines? Next let us learn more about the detailed process of custom PVC figurine toys for customers:

First, Get the customer's design

Determine the customer's project characters or other prototypes of the original painting settings, to determine the number of production, to determine the cost of input, to determine the size of the statue proportion. Note the difference between the uncoloured prototype and the final effect.

Depending on the situation, before the production of the prototype begins, upfront Dememg Toy will give an initial quote based on the relevant information provided by the artist's artwork.

During this period, the client will be informed about: prototyping, mass production, packaging, quality level of the figures, exact date of mass production, delivery date (at least one month's lead time in case of accidents), mode of delivery, payment methods, and so on. According to the result of our final negotiation, the brand client can decide the sufficient time for publicity, booking volume and release date in this preliminary consultation stage.

Second, the prototype stage:

1. 3D printing prototype production: Demeng Toys will have professional business personnel docking communication prototypes, artists and other brand personnel, in the confirmation of the design is correct for 3D modelling, modelling will be given after the completion of the model of the PVC figurine six views to the customer to confirm the details of the figurine model, there are errors or need to adjust the place for modification, the final output for the .stl/.obj/.stp format. The final output is in .stl/.obj/.stp format, because there are differences between the 3D model and the real thing, the printing should be confirmed, does not comply with the settings or problems need to be reworked to modify the model and reprint the prototype of the figurine. After printing out the whole piece needs to be sanded or directly sprayed wax after moulding for GK parts.

2. the print parts sanded after the colour, the colour mode according to the complexity of the colour pattern to choose a different process, generally simple patterns can be sprayed or hand-coloured, the complexity of the need to choose the pad printing or water paste and other processes to achieve the colour.

3. When all the parts of the colouring is completed can be assembled into a complete figurine prototype, the assembly method is generally through the special environmentally friendly adhesive glue way for the assembly of the figurine.

Third, the figurine prototype disassembled with the original model backup confirmation:

In order to better paint integrity, reversibility, playability, the production of handmade office boy when the disassembly is a very important step. The design of the disassembled parts is completed by Demeng Toys' professional 3d modeller.

When disassembling the parts, pay attention to the size of the interface, whether it can be smoothly closed without loosening and other issues.

When disassembling the parts, we also need to consider the difficulty of painting and injection moulding. After dismantling the resin mould.

Fourth, steel mould sculpture casting:

Steel mould sculpture casting according to the shape of the PVC Figurines, the degree of difficulty and the number of different, spend time is also different, the trial mould rework is also a lot. General 3500-5000 U.S. dollars or so can make a steel mould, steel mould size for 1/10 scale hand puppet quarter parts (different shape different row mould different prices).

For the layout of the mould, we need to consider the strength of the parts, volume distribution, injection difficulty, and the colour of the parts (usually uniform white, all the colours are painted, and the colour of the parts are painted with a serious colour difference, but the skin colour parts have to be individually designed and divided into parts).

The steel mould should be repaired when the injection reaches 3,000 pieces, the industry practice.

Fifth, the first sample confirmation:

After the steel mould is done, you need to try the mould, that is, on the machine for the initial injection, in addition to ignoring the surface is not smooth, carefully and prototype comparison, carefully check any PVC figure details, including interface connection, the location of the water outlet, whether the sub-parts are reasonable, such as hair and other weak position is deformed or missing, appropriate baking to see whether the deformation of the deformation of cracked face and other key parts of the deformation of the overall shrinkage is not great, whether the posture is deformed, whether it is able to stand stable The centre of which, and stand test.

Sixth, steel mould polishing:

After the completion of the test mould to confirm that there is no error, you can polish the inner surface of the steel mould smooth, the polishing process can not lose the important details of the mould, after polishing the fit and shape of the parts will be subtle changes.

Seven, PVC figurine formal sample confirmation:

The same as the initial sample confirmation, and to check whether the surface is smooth, whether there is overflow, whether there are stripes, whether the parting line is in the acceptable range, test the ability to stand, decide the PVC hardness of each part and whether there are ABS parts.

Eight, packaging programme:

Prototype stage has been basically able to confirm the size of the figurine package, at the initial stage try to confirm the form of packaging, the material of the carton, the thickness of the paper grams, whether to add blister, open window, whether to add bright strip, special packaging and other issues.

Nine, oil spraying mould production:

The oil spraying mould will be made after the PVC official sample is confirmed, the oil spraying mould needs the prototype colouring sample for reference, and the oil spraying mould is related to the painting quality of the hand puppet. Complex and important details such as eyes can be achieved by oil spraying mould or transfer printing, how many oil spraying moulds there are will be how many painting processes.

The oil spraying mould must be clamped, not loose, the spraying surface is completely exposed, does not require too much baking treatment can be put in, fit well, the pattern position is accurate and clear, the thinner the copper sheet around the spraying range, the better. The effect of spray paint without overflow of colour, non-staining paint, spray paint many times after timely cleaning.

Ten, pad printing steel production:

Select the pad printing process should not be too large a pattern size, try to maintain consistency with the design of the prototype, the direction is correct, the colour is accurate, pad printing on different surfaces of the curvature and deformation should also be taken into account. The fixed mould for pad printing should also fit well without displacement or deformation. Pad printing can be divided into single-colour pad printing and multi-colour pad printing.

Eleven, pre-production sample making and confirmation:

Mass goods sample production should follow as much as possible to ensure that the large goods production process under the finished product, from the PVC official sample of a small part of the mass production, painting and pad printing, and finally assembled, and at the same time need to be coordinated with the brand to monitor and adjust, and ultimately make the shape, colour, pattern and prototype samples are the same.

During this process, process quality assessment and final quality grade confirmation are carried out, based on the contract, to determine the quality of mass production. If there are problems with the centre of gravity and base, additional elements such as staking and steel nails in the legs are required. A certain number of mass production samples are produced and retained by both parties for confirmation and archiving. At the same time also for the confirmation of the packaging samples, pay attention to the fit of the blister and packaging, in order to the hand puppet can be perfectly placed and the size of the box is appropriate.

Mass production:

Mass production, injection moulding and painting link no problem, brand customers if time to cooperate with the assembly workshop carefully supervise, or assembly bonding work guidance, or assist in correcting the workers are not right, remind the assembly supervisor notes, determine the assembly process.

Packaging and shipping:

Quality supervision and inspection before packing, according to the specific requirements of the cost of screening out defective products, good quality supervision. Choose excellent logistics and way when packing and shipping.

Demeng Toys, a professional PVC figurine manufacturer, has been producing each PVC art figurine according to the highest standards, providing reliable quality assurance and quality production service for customers who need customised pvc figurines.