How to Make Vinyl Toys

Vinyl toys are collectible figures made from PVC/soft vinyl using a repeatable, mold based workflow that balances art and engineering.

Define your character’s theme, size, pose, and any articulation or accessories. Common display sizes range from about 3–12 in+.

Create multiple orthographic views (front/side/back) to lock proportions and details before you sculpt or model.

Tools: sketchbook, pencils, and digital tools like Adobe Illustrator/Procreate for concept art; later move to ZBrush/Blender for 3D.

Planning for production: decide early whether your vinyl toys will be static or articulated, and choose a target age and packaging style (e.g., blind box, window box, backing card) to guide scale, detail, and compliance.

Choose your workflow:

Clay sculpting: build an armature (wire frame), add clay in layers, then refine textures and details.

3D digital sculpting: model in ZBrush/Blender, then 3D print a master to refine by hand.

The prototype is your “golden sample” for making the mold and testing scale, balance, and details.

Iterate until the prototype feels right for a vinyl production run; check parting lines, undercuts, and how colors and textures will translate after molding and painting.

Prepare the master: apply a release agent to prevent sticking.

Build a mold box around the prototype, leaving space for silicone.

Mix and pour silicone rubber slowly to avoid bubbles; ensure full coverage of all details.

Allow the silicone to cure (time varies by product), then open the mold and remove the master. For complex shapes, use a twopart mold to capture undercuts.

Label sprues and parting lines clearly so your vinyl toys demold cleanly and assemble consistently.

Prepare the mold: apply release agent inside the silicone mold.

Mix liquid vinyl (PVC) or a suitable casting material according to the manufacturer’s instructions; pour into the mold, tapping gently to release trapped air.

Let the vinyl cure fully, then demold. Trim any flash and sand lightly for a clean finish.

Note: industrial PVC injection molding uses metal molds and is suited to large runs; small indie projects typically start with silicone molds + casting. For higher volumes, plan your gating, venting, and tolerance to keep your vinyl toys dimensionally stable.

Surface prep: clean, sand, then apply a primer suitable for vinyl.

Painting: use acrylics or spray paint; for pro results, try airbrushing and layer colors for depth. Seal with a compatible clear coat if needed.

Assembly: join parts with a strong, toysafe adhesive. If your design includes movable joints, use appropriate connectors (e.g., pins/ball joints) and test fit before gluing.

Packaging: design illustrated backing cards or boxes that reflect your character and story; this adds value and appeal for display or retail.

Safety and compliance: determine your target age and applicable toy standards (e.g., EN71, ASTM F963, CPSIA, GB 6675), then perform required tests (small parts, sharp points/edges, flammability, mechanical/chemical safety). If producing at scale, work with vetted factories and implement quality control checks.