Vinyl Dip Molding
The Dip Molding Process - A basic understanding of dip molding can be simplified by relating it to the art of candle making. A heated metal mold is immersed or "dipped" in a tank of liquid plastisol (PVC). The heat from the mold attracts the cool plastisol and the part is formed. The molds are extracted from the liquid and heat cured. After the parts are cured, they are cooled and stripped from the molds.
Materials - Our extensive material compounding capabilities not only allow us to offer the largest selection of materials in the industry, but we are also able to achieve the lowest possible cost on our plastisol. By mixing our own plastisol we avoid the mark-up that most molders pay to their compounder. By recycling the plastisol expensive disposal costs are eliminated and environmental benefits are gained.
The breadth of our business allows us to offer many standard formulas and colors suitable for most applications. However, if none of our existing formulas work for your application, we can utilize our research and development lab to develop a new material. Over the years, we have developed over 500 formulas for the varying needs of our customers.
Engineering and Prototypes - When we receive your specifications, our engineering staff utilizes their expertise to explore all possibilities in determining the best material and the best process for the project. Our engineers have designed parts ranging from our standard styles to more complicated engineered custom parts made to solve some of the most difficult problems. Within the scope of our vinyl dip molding (VDM) process alone, we have developed thousands of parts and designed hundreds of proprietary custom tools. Our goal is to design your part in the most cost effective manner and to design it to deliver the highest level of performance required.
Not only do we have over 50 years of design experience, but we utilize some of the most sophisticated design and manufacturing software. We've grown with CAD CAM technology beginning in the early years of AutoCAD, then Pro-Engineer software. Collaborating with all our locations, we work seamlessly using PTC Creo and Siemens NX programs to seamlessly integrate the tooling fabrication process.
One of the primary benefits of dip molding is related to its inexpensive and accurate prototyping process. With a dedicated sample lab producing parts daily, we are able to provide prototypes for engineering and marketing tests at an insignificant cost.
Equipment - We utilize numerous machine designs to make your parts in the most cost effective manner. Most dip molders utilize flexible machines that allow them to make many different sizes, shapes, and volumes on one machine. Unfortunately, with flexibility comes inefficiency. By having numerous machine designs, we can choose the style that will run your product in the most cost effective manner in regards to tooling investment and piece price.
Our Specialty - With over 50 years of experience, our custom dip molding capabilities are second to none. We have pioneered the market in regards to the double dip and triple dip process and invented numerous materials including Tuffoam®, Softex®, Vynaprene®, and Polysuede®. As a fully integrated manufacturer, we strive to offer our customers the best value in the industry.
Benefits of Dip Molding
- Low tooling costs...typically a fraction of injection molding
- Quick and inexpensive prototypes
- Short lead-times on custom tooling...weeks versus months
- Innovative materials and textures
- More vibrant colors can be achieved with vinyl
- No internal stress molded into parts
- Large parts can be made without significant tooling investment
- Multi-Dipping capabilities allow us to design products with two colors or materials on one part - typically used for making products with durable inside liners and more consumer friendly exteriors
Benefits of Dip Molded Caps and Plugs
- Caps of varying lengths can be made with no tooling charge
- Vinyl material stretches to fit odd shapes and easily conforms to beaded or flared tubes
- Vinyl material will not crack or split like Low-Density Polyethylene
- Vinyl material does not shred when capping or plugging threaded items