How do you manufacture pvc rubber dolls toys

  The manufacturing process of PVC rubber dolls toys (typically referring to soft PVC dolls, as pure rubber is less commonly used in such toys) involves multiple technical steps and quality control links. The following is a detailed breakdown of the standard production process:o

1. Raw Material Preparation

• Main Material: Soft PVC resin (mixed with plasticizers, stabilizers, pigments, etc.).Auxiliary Materials: Metal skeletons (for poseability), fabrics (clothing), accessories (eyes, hair, etc.), and eco-friendly pigments for coloring.
  • Plasticizers (e.g., DOTP or eco-friendly alternatives) determine the softness; stabilizers prevent thermal degradation during processing.
• Material Testing: Ensure compliance with safety standards to avoid harmful substances like phthalates.

2. Mold Design and Fabrication

• Design Phase:
  • Use CAD software to create 3D models of the doll, defining details (facial features, body proportions, joints).
  • For articulated dolls, design detachable parts (head, limbs) with joint structures.
• Mold Making:
  • Mold Materials: Commonly made of stainless steel or copper (for slush molding) or aluminum alloy (for injection molding).
  • Mold Types:Surface Treatment: Etch textures (skin pores, clothing patterns) onto the mold surface for realism.
    • Slush Molding (Most Common for Soft PVC): Split molds (e.g., head, body halves) with hollow cavities.
    • Injection Molding: Used for hard PVC parts (accessories like shoes, hats).

3. Plastic Molding Process

A. Slush Molding (Key Process for Soft PVC Dolls)

1. Mold Preheating: Heat the split mold to 180–220°C to ensure uniform material adhesion.
2. PVC Paste Filling: Pour liquid PVC paste (mixture of resin, plasticizer, and pigments) into one half of the mold.
3. Rotational Casting: Rotate the mold slowly (both horizontally and vertically) to allow the PVC paste to coat the inner surface evenly.
4. Curing: Maintain heat for 10–20 minutes to melt and solidify the PVC, then cool the mold to room temperature.
5. Demolding: Open the mold to remove the semi-finished doll, trimming excess material (flash) around the edges.

B. Injection Molding (for Hard Parts)

• Inject molten PVC into a closed mold under high pressure, cool, and demold to form parts like hands, feet, or accessories.

4. Post-Molding Processing

• Trimming and Smoothing: Use scissors or machines to remove flash, then sand edges for a smooth finish.
• Assembly of Skeletons: Insert metal or plastic skeletons into the body for poseability (e.g., wire frames in limbs).
• Joint Installation: Attach limbs to the body using snap-fit joints, screws, or adhesive.

5. Decoration and Finishing

• Painting:
  • Hand-paint details (eyes, lips, facial expressions) with non-toxic paints.
  • Airbrushing for gradient effects (e.g., skin tone shading).
• Applying Accessories:Surface Treatment: Spray a matte or glossy protective coating to prevent paint chipping and enhance durability.
  • Glue on synthetic hair (root by root for realism), install plastic eyes, or attach fabric clothing.
  • Add decals (tattoos, clothing patterns) via screen printing or heat transfer.

6. Quality Control

• Visual Inspection: Check for defects (color fading, uneven surfaces, missing parts).
• Functionality Test: Ensure joints move smoothly and skeletons are secure.
• Safety Testing:Durability Test: Simulate handling (bending, squeezing) to ensure resistance to deformation.
  • Pull test (accessories must not detach easily to avoid choking hazards).
  • Toxicity test (lead, phthalate content in materials).

7. Packaging and Shipment

• Packaging Design: Place dolls in blister packs, cardboard boxes, or custom packaging with brand labels.
• Accessory Inclusion: Add manuals, certificates (CE, ASTM), or extra accessories (outfits, props).
• Warehousing and Distribution: Sort by order and prepare for shipment, ensuring packaging protects against transit damage.

Key Technical Points and Trends

• Eco-Friendly Innovations: Use bio-based PVC or water-based pigments to meet growing environmental requirements.
• Customization: 3D printing technology allows small-batch production of personalized dolls (e.g., custom facial features).
• Safety Regulations: Compliance with regional standards (e.g., CPSC in the U.S., REACH in the EU) is mandatory to enter global markets.