- PVC injection molding produces solid figures with sharp details by forcing molten plastic into a steel mold under 800–1,500 tons of clamping force.
- Barrel temperature: 180–220°C. Mold temperature: 30–60°C. Cycle time: 15–45 seconds per shot depending on part size.
- Mold costs: USD 3,000–15,000 (higher than rotocasting). Per-unit costs drop significantly at high volumes (1,000+ pieces).
- Rigid PVC (Shore D 60–80) is used for sharp-detail collectibles. Flexible PVC (Shore A 70–90) is used for figures with some give.
- A single injection mold can produce 2,000–5,000 cycles per day, making it the fastest process for mass-producing collectible figures.
How Are PVC Figures Made Using Injection Molding?
PVC injection molding is the dominant manufacturing process for mass-produced collectible figures — anime statues, character figurines, and retail toys. Unlike rotocasting, which produces hollow figures by coating a rotating mold, injection molding forces molten PVC into a sealed steel cavity under extreme pressure, producing solid parts with razor-sharp detail.
Here's what happens on the production floor: PVC pellets are fed into a heated barrel (180–220°C). A reciprocating screw pushes the molten plastic forward and injects it into the mold cavity at pressures up to 1,500 tons. The plastic fills every corner of the mold — capturing fine textures, sharp edges, and intricate surface details that rotocasting simply can't achieve. The mold cools the plastic in 15–45 seconds, opens, and ejects the solid figure.
A single mold can run 2,000 to 5,000 cycles per day. That's why injection molding is the go-to process when you need thousands of identical, high-detail figures.
The PVC Injection Molding Process: Step by Step
Step 1: Material Preparation
PVC pellets are dried and fed into the injection molding machine's hopper. The type of PVC depends on the figure's requirements — rigid PVC for hard, detailed figures, or flexible PVC (with plasticizers) for figures that need some bend. The pellets are heated in the barrel to 180–220°C until they reach a molten, flowable state.
Temperature control is critical here. Overheating PVC above 230°C causes thermal decomposition and releases hydrochloric acid gas — which is why modern injection molding machines have precise temperature zones and ventilation systems.
Step 2: Injection and Packing
The reciprocating screw pushes the molten PVC forward at high speed and injects it into the mold cavity through a gate (a small opening in the mold). The injection pressure ranges from 800 to 1,500 tons of clamping force, depending on the part size and complexity. After the cavity fills, the machine holds pressure for 2–5 seconds to pack the material tightly and prevent shrinkage.
Step 3: Cooling and Ejection
Cooling channels inside the mold circulate water or oil to bring the plastic temperature down. The cooling time depends on part thickness — thin walls cool in 15 seconds, thick sections take 35–45 seconds. Once the part is solid enough, the mold opens and ejector pins push the figure out. The cycle repeats.
Step 4: Trimming, Painting, and Assembly
The raw figure comes out with a gate mark (where the plastic entered the mold) and possibly some flash (thin excess material at the parting line). Workers trim these, then the figure moves to painting. Base colors are applied with spray guns through masks. Fine details are hand-painted. Multi-part figures are assembled after painting — heads pegged onto bodies, accessories attached.
PVC Injection Molding vs. Rotocasting: When to Use Each
| Factor | PVC Injection Molding | Rotocasting (Vinyl) |
|---|---|---|
| Structure | Solid | Hollow |
| Detail level | Excellent (sharp edges, fine textures) | Good (soft edges) |
| Cycle time | 15–45 seconds | 3–8 minutes |
| Daily output per mold | 2,000–5,000 cycles | 20–50 cycles |
| Mold cost | USD 3,000–15,000 | USD 2,000–8,000 |
| Best volume range | 1,000–100,000+ pieces | 300–2,000 pieces |
| Best for | Anime figures, retail collectibles | Designer art toys, sofubi |
The choice comes down to volume and detail. If you need 5,000+ identical figures with sharp detail, injection molding is the only practical option. If you need 300–500 art toys with a handmade feel, rotocasting is more cost-effective.
What Type of PVC Is Used for Collectible Figures?
Two types of PVC are used in collectible figure production:
- Rigid PVC (unplasticized): Shore D hardness 60–80. This is the standard for most anime figures and collectible statues. It's hard, holds sharp detail, and has excellent dimensional stability. Most PVC art figurines use rigid PVC.
- Flexible PVC (plasticized): Shore A hardness 70–90. Used for figures that need some flexibility — like articulated joints or squeezable toys. Contains 20–40% plasticizer by weight.
Some manufacturers blend PVC with ABS (acrylonitrile butadiene styrene) to improve impact resistance. ABS adds toughness without sacrificing detail. This blend is common in action figures and toys that need to survive drops.
How Much Does a PVC Figure Mold Cost?
PVC injection molds are more expensive than rotocasting molds because they need to withstand extreme pressure (up to 1,500 tons) and thousands of cycles. Here's the cost breakdown:
| Mold Complexity | Cost | Typical Use |
|---|---|---|
| Simple (2-part, 2 cavities) | USD 3,000–5,000 | Small accessories, bases |
| Medium (4–6 parts, multi-cavity) | USD 5,000–10,000 | Standard collectible figures |
| Complex (8+ parts, hot runner) | USD 10,000–15,000 | High-detail anime figures |
Mold making takes 30–45 days. The mold is CNC-machined from hardened steel (typically P20 or H13 grade), polished to a mirror finish on the interior surfaces, and fitted with cooling channels, ejector pins, and a gating system.
Need PVC injection molding for your collectible figures? We run both injection molding and rotocasting in our Shenzhen factory. Send us your 3D model or concept art and we'll recommend the best process for your design, volume, and budget.
Get a quote · WhatsApp: +86 13544127654 · Email: info@demengtoy.com
Frequently Asked Questions
How are PVC figures made using injection molding?
PVC figures are made by heating PVC pellets to 180–220°C until molten, then injecting the molten plastic into a steel mold under high pressure (800–1,500 tons clamping force). The plastic cools and solidifies inside the mold in 15–45 seconds. The mold opens, ejector pins push the solid figure out, and it goes to painting and assembly.
What is the difference between PVC injection molding and rotocasting?
PVC injection molding produces solid figures with sharp details by forcing molten plastic into a sealed steel mold under high pressure. Rotocasting produces hollow figures with soft edges by rotating a mold while heating liquid PVC, which coats the interior walls. Injection molding is better for detailed collectibles; rotocasting is better for art toys and sofubi.
What temperature is used for PVC injection molding?
PVC injection molding uses a barrel temperature of 180–220°C and a mold temperature of 30–60°C. The exact temperature depends on the PVC compound formulation — rigid PVC needs higher temperatures than flexible PVC with plasticizers. Overheating PVC above 230°C causes decomposition and releases hydrochloric acid gas.
How much does a PVC figure mold cost?
PVC figure injection molds cost USD 3,000–15,000 depending on complexity. A simple 2-part figure with 2 cavities costs USD 3,000–5,000. A complex figure with 8+ parts, multi-cavity molds, and hot runner systems costs USD 10,000–15,000. Mold making takes 30–45 days.
What type of PVC is used for collectible figures?
Collectible figures use either rigid PVC (unplasticized, Shore D 60–80) for hard, detailed figures, or flexible PVC (plasticized, Shore A 70–90) for figures with some give. Most mass-produced anime figures and collectible statues use rigid PVC for sharp detail. Some manufacturers blend PVC with ABS for impact resistance.
How long does PVC injection molding take per cycle?
A typical PVC injection molding cycle for a collectible figure takes 15–45 seconds, depending on part size and wall thickness. Small parts (1–2 inches) cycle in 15–20 seconds. Medium parts (3–6 inches) take 25–35 seconds. Large parts (8+ inches) take 35–45 seconds. A single mold can run 2,000–5,000 cycles per day.
Is PVC injection molding safe for toy production?
Yes, PVC injection molding is safe for toy production when using food-grade or toy-grade PVC compounds that comply with EN71 (Europe) and ASTM F963 (US) standards. Modern PVC compounds for toys are free from harmful phthalates and heavy metals. The finished figures are inert and non-toxic.
What are the quality control steps for PVC injection molded figures?
Quality control for PVC injection molded figures includes: dimensional accuracy check (±0.1mm tolerance), surface defect inspection (sink marks, flash, short shots), color consistency verification against Pantone standards, structural integrity testing (drop test, stress test), and chemical safety testing (heavy metals, phthalates migration per EN71/ASTM F963).
We run both injection molding and rotocasting lines in our Shenzhen factory. This technical guide comes from our production floor — the temperatures, pressures, and cycle times we use every day.
Connect on WhatsApp- ASTM International, ASTM F963 Standard Consumer Safety Specification for Toy Safety
- European Committee for Standardization, EN 71 Safety of Toys
- Verified Market Research, Figurine Market Size Forecast 2025–2033