What materials are used in dip moulding?

Jul 13, 2023 | Dip moulding

Dip moulding is used to produce many of the protective products in the Caplugs range. This blog post explains which materials are suitable for dip moulding and the advantages of this production method.

The shaping qualities of PVC

As a general rule, dip moulding is only possible with plastics that form well around a mould in liquid form and under high temperatures. Polyvinyl chloride (PVC) is the most commonly used material for dip moulding because it is easy to use and affordable. Other materials frequently used for dip moulding are thermoplastics, such as polythene, polypropylene, polystyrene, polyamide and polycarbonate.

Ideal for protective and masking products

A characteristic of the materials used in dip moulding is that they form a thin skin around the mould like a liquid. At Caplugs, dip moulding uses a plastisol of polyvinyl chloride (vinyl or PVC) beads in a liquid plasticiser. When heated, the vinyl beads absorb the plasticiser, swell and melt into a liquid substance similar to resin. The vinyl plastisol can then be coloured with pigment. Caplugs uses the standard colours black, yellow and red. The aluminium mould used for dip moulding has exactly the shape of the final plastic product. When the mould cools to below 60 °C (140 °F) after dipping, the PVC plastisol cures to a flexible rubbery form. The ready-moulded product is then easily removed from the mould.

Excellent price-quality ratio

The biggest advantage of vinyl dip moulding is the ability to produce large series of vinyl products at a low cost. Depending on the size of the product, several vinyl caps can be made at the same time. There are moulds of three caps, and up to 200 caps can fit on a rack at a time. During the dipping process, the thickness of the material can be adjusted without changing the mould. Even the most complex parts can be easily removed from the mould thanks to plastisol’s elasticity.

Dip moulding – ideal for product protection solutions

In addition to all the qualities of dip moulding mentioned above, the vinyl plastisol used by Caplugs has a number of other favourable properties:

Electrical resistance

Flame retardant

Noise-reducing

Chemical and oil-resistant

Shock and abrasion-resistant

Corrosion and ultraviolet (UV) radiation-resistant

Large temperature range from -50°C to +120°C

Caplugs – a specialist in dip and injection moulding products

The standard protection and masking products can be found in the extensive Caplugs catalogue. For a custom-made product for a specific application, please contact us.

What is a mould and what does Caplugs use it for?

Jun 16, 2023 | Dip moulding

Caplugs uses aluminium moulds to produce standard and custom-made products for dip moulding and injection moulding. This article explains what a mould is and why it is an essential part of the production process for our protective solutions.

A mould is a form that carries a negative or reverse impression of the product to be made. Aluminium is used to get the most detailed shape (geometry) and the exact dimensions for the plastic part to be produced.

Moulds for injection moulding

An injection mould consists of two parts, the injection side and the ejection side. This hollow container is shaped exactly according to the product specifications. The parts are made so that the moulded product can be easily and quickly removed from the mould. In injection moulding, the liquid product material is injected under pressure into the cavity of the injection mould. After the trapped air escapes, the liquid plastic solidifies in the cold cavity and takes the shape of the desired product. After solidifying and removal from the matrix, the product is ready for finishing.

Moulds for dip moulding

Caplugs use a CNC machine to make the aluminium moulds for dip moulding. In dip moulding, unlike injection moulding, the moulds are immersed in liquid vinyl, causing the material to form a layer on the mould. The mould is then heated again briefly to cure the plastisol. After curing, the formed product is blown off the mould with compressed air and is ready for possible finishing.

Vinyl-formed products are blown off the mould

Mould determines geometry and dimensions

The above explanation already makes clear that moulds are essential in the production of vinyl caps and plugs. Caplugs, therefore, pays a lot of attention to making and constantly improving moulds for injection and dip moulding. In addition, much attention is paid to cooling, heating and venting the injection mould, because these aspects determine the quality and purity of the product.

Reuse again and again

Moulds by Caplugs for dip moulding and injection moulding are always thoroughly cleaned after use and inspected for any internal and/or external damage. This is because a clogged or cracked cooling or venting channel or unevenness in the mould surface will have immediate consequences when reused during a subsequent production cycle. Mould reuse applies to standard protection products used in industry, automotive, aviation, aerospace and (petro)chemicals. In addition, Caplugs use so-called multiple moulds. This enables the production of several identical products at the same time during one run.

The perfect mould has its price

Mould making is labour-intensive precision work and a relatively large investment that pays for itself in the long run, which is why Caplugs uses existing moulds wherever possible. The cost of an injection mould is determined, among other things, by the complexity, geometry of the product (part) and the number of products that can be made simultaneously within one injection cycle. Prices for dip moulding and injection moulding moulds vary enormously. For a dip moulding mould, you can expect to pay a few thousand euros, while a mould for injection moulding can go up to €150,000.

Unique moulds for customised protection solutions

To manufacture custom-made products, Caplugs makes moulds that match customers’ product design and specifications exactly. These moulds are saved for possible future production runs, which means customers do not need to invest again in making new moulds.

The quality of the mould and products are key

Safety during production and the quality of the finished product are always at the heart of Caplugs. Customers must be able to rely on the protection solutions at all times. Would you like more information about products made by injection moulding or dip moulding? Or are you looking for a customised product for your specific application? Then get in touch with the Caplugs team.

Dip moulding offers almost unlimited production possibilities

Jun 2, 2023 | Dip moulding

Caplugs has an extensive range of seals and protective products made by vinyl dip moulding. This blog post explains the dip moulding process and the possibilities and advantages this production method offers.

A bath with liquid plastisol forms the plastic product

The underlying principle of the dipping process is a bath of liquid polyvinyl chloride (PVC) into which aluminium moulds are immersed. The PVC adheres to the mould like a skin, taking on the shape of the final product. The temperature of the mould and the immersion time determine the thickness of the plastisol. After dipping, the mould is heated again so the plastisol melts and hardens. The vinyl products are then removed from the moulds using compressed air.

The steps in dip moulding

The mould is heated.

The mould is fully immersed in heated liquid plastisol.

When the set immersion time is over, the mould is removed from the bath.

Once out of the bath, the vinyl-coated mould is heated again so that the plastisol melts and cures.

The mould encased with the plastisol is cooled to room temperature.

After cooling, the vinyl product formed through the dip moulding process is detached from the mould.

Suitable for standard and customised products

Dip moulding is mainly used for making plastic products with complex geometry. An excellent example of this is the range of vinyl caps, sleeves and covers from Caplugs. In addition to our standard products, Caplugs also uses dip moulding for fully customised vinyl products with unusual shapes and dimensions.

Vinyl caps, sleeves, and covers

Dip moulding is often used to produce larger series of vinyl caps as the customised moulds can be used repeatedly. For a high-volume series, the dipping speed and oven temperature settings can also be standardised. In the production of non-standard protective products, special moulds need to be designed and made. In this case, all settings for the dip moulding process have to be carefully redefined. Caplugs provides a full-service custom moulding process from prototype to finished product, including advising customers on finding the most cost-efficient solution for their product application.

Dip moulding has many advantages

Besides a favourable price-quality ratio, dip moulding has a number of other advantages. For instance, vinyl dip moulding and vinyl dip coating produce seamless and even products. In addition, the customer can determine the level of finishing in terms of colour, textures and thicknesses. Matt, glossy, and in whatever form, dip moulding offers almost unlimited possibilities. For more information, view the Caplugs product catalogue or contact us.

What is dip moulding?

Apr 7, 2023 | Dip moulding, Uncategorized

Dip moulding is a manufacturing process in which a heated aluminium mould is immersed in a bath of liquid plastisol. The mould is then slowly withdrawn to allow the material to adhere and leave a thin layer on the mould. The shaped part is then cooled and separated from the mould. Dip moulding is used to make a variety of products, such as vinyl protective caps, but is also used as a coating for tools and equipment. The dipping technique is very useful for making items with complex shapes or small details.

Dip moulding products

Caplugs makes protective caps with the dipping moulds for a variety of applications, such as protecting threads, fittings, tubes and other fragile parts during transport and storage. Caplugs has the following dip-moulded products in its range:

Square vinyl caps

These end caps are made of durable and flexible vinyl material. The capping square can be used as end caps for pipes and bars With that, the square vinyl caps provide protection against dirt, dust and other contaminants that can damage components. They are available in various sizes and colours and can be customized to meet specific customer requirements.

Round vinyl caps

Round vinyl caps are easy to install and remove due to the flexible material and provide a sleek finish. Additionally, they stay firmly in place and offer protection against bumps and scratches. Round caps are available in standard sizes and can also be customized to meet specific requirements.

Verzameling rechthoekige vinyl doppen in zwart en geel.

Rectangular vinyl caps

The rectangular vinyl finishing caps and hand grips have a flat and closed end, therefore making them quick and easy to apply. The flexible material that the rectangular caps are made from ensures a good fit to protect and cover finished products, such as plate steel, box sections and bars.

Pull Tab vinyl caps

Caplugs’ pull tab vinyl caps have an ergonomic design, giving them a better gripping surface and requiring less pulling force for removal. The flat grip at the top means the vinyl cap can be removed by hand and no other tools are needed. This reduces the risk of damaging the product. Due to the flexible material, the pull tabs have an excellent fit for a wide range of purposes, such as finishing and masking of products.

Gele vinyl sleeve ontstaan met dip moulding

Vinyl sleeves

Caplugs’ vinyl sleeves are made of durable vinyl and come in different sizes to fit different sheet sizes. The smooth surfaces of these vinyl sleeves ensure that the records are protected from scratches as well as damage. The transparent colour of the sleeves makes it easy to identify the sheets and read what is printed on them. Moreover, Caplugs’ sleeves are easy to open and close, which increases the ease of use making the sleeves an ideal choice for protecting valuable equipment and tools.

Vinyl covers

Caplugs’ vinyl covers are used for various pole protection applications. They protect poles from dust, dirt moisture and scratches. Caplugs’ vinyl covers are available in different sizes and are easy to use and apply. The covers provide an extra layer of protection, are high-quality and durable, making them long-lasting as well as a good investment for pole protection in, for example, the agricultural industry.

Wat is vinyl coating?

Dip moulding is commonly used to produce hollow moulded parts, but it can also be used to apply a layer of vinyl over a metal product. The purpose of vinyl coating is to improve the quality of metal products and protect the metal from corrosion as well as damage.

Caplugs makes grips for tools and equipment, plugs for electrical connectors and other custom-made components for industrial applications by the use of vinyl coating.

Het afblazen van vinyl dopjes na de dip moulding.

Vinyl gecoate handvatten worden in een doos verpakt.

For which applications is dip moulding used?

Caplugs provides solutions for various industries, including automotive, aviation, medical, electronics and the food industry. With expertise in product design and the use of various manufacturing techniques, in particular dip moulding, is Caplugs able to provide customers with tailor-made solutions that meet their specific needs.

Questions or curious about the possibilities for your product? Then contact us without obligation!