PLASTISOL COATING

PLASTISOL COATINGS AND MOLDINGS

PLASTISOL EXPLAINED

HOW DOES PLASTISOL COATING WORK?

You might not realize how prevalent plastisol coated products and equipment are in the world today. Take a look around! Exercise equipment, tool handles, and gas pump handles are all coated in plastisol using the dip coating method. 

Vinyl Plastisols are dispersions of special, fine particle size PVC resins in plasticizing liquids. These materials are liquid at room temperature. However, as the compound is heated, fusion takes place and the liquid is converted into a tough, homogenous mass. Plastisol can add a smooth finish to products, and be used to coat metals, glass, ceramics and plastics, as long as they are able to withstand the heating portions of the dip coating process. When the coating cools, it is highly regarded for its physical properties and chemical resistance. Plastisol coatings are applied to many different products in order to supply them with aesthetic qualities, tactile softness and gripping power.
 
This process of plastisol coating is commonly used when a part requires a thick coating, or only a specific area of the part requires coating. This coating is applied through a dip process where the part is preheated and fully, or partially, submerged into a liquid tank of PVC and then post cured. A range of thickness can be achieved through the use of controlled temperature, dwell time in the liquid, and speed of extraction. Popular tools like pliers or screwdrivers are many times fitted with a plastisol coating on their handles to help the user maintain a solid grip.

Plastisol can provide many advantages including:
  • Vibration damping
  • Noise reduction
  • Abrasion resistance
  • Chemical resistance
  • Electrical Resistance (Dielectric Strength)
  • Soft feel and look
  • Finishes that range from high gloss to matte to subtle textures
  • Variety of standard colors available
  • Able to custom match most colors
Plastisol dip coating is popular because it’s simple and cost-effective, with minimal waste in the process. 
  • Hot Dip Coating is the process in which an object is heated, dipped in plastisol and then placed in a heated chamber where fusion takes place.
  • Hot Dip Molding is used where the interior geometry is more important than the exterior – like in conformal caps and grips. Tooling costs for a dip mold can be less than 10% of injection mold tooling while comparing favorably in production and material costs.
  • Cast Molding involves dispensing plastisol into a mold, placing it in an oven and then heating it so the plastisol fuses into the finished part. This process is capable of producing multi-colored parts. 
  • Rotational Molding is a method that involves placing a limited amount of plastisol in a mold and then rotating it as heating takes place, so the liquid is equally distributed. This is used to create hollow products.
  • Cold Dip Coating is used mostly for thin coatings of plastisol. In this process, the object is dipped in plastisol without preheating, and then placed in a heated chamber.
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FREQUENTLY ASKED QUESTIONS ABOUT PLASTISOL


Plastisol is one of the most popular plastic coating materials available. Budget-friendly and fully customizable, this workhorse coating is suited to countless applications and environments. Here are answers to some of the most frequent questions we receive about this versatile coating.

  • What are plastisol's greatest advantages?

    Plastisol is especially popular as a plastic coating because it is:

    • Extremely durable, resisting impacts, abrasions, and other damage
    • Highly resistant to water and most chemicals
    • Effective in extreme temperatures and hazardous conditions
    • Able to improve comfort and safety
    • Available in any color and with many textures and special effects
    • Very cost-effective
  • How is plastisol applied?

    Most commonly, preheated parts are dipped into liquid plastisol, then heat-cured to set the coating. Occasionally, the cold dip method is used for parts which won't withstand preheating but which tolerate heat-curing. 

  • How does the automotive industry use plastisol?

    Many parts and products in cars and trucks make use of plastisol coatings, adding comfort, safety, and helping eliminate BSR issues.


  • What projects are best suited to plastisol coatings?

    Ideal applications for plastisol are those which take advantage of its soft, rubbery feel, excellent temperature and electrical properties, and exceptional durability.

  • Is plastisol a safe coating?

    Yes, plastisol is non-toxic, requires no solvents, is BPA-free, and is available in phthalate-free formulations.

  • What are the most common uses of plastisol coatings?

    Plastisol coatings are most often used for:


Many people consider plastics and the environment to be incompatible, but it doesn't have to be that way. Plastisol is one material that is being made increasingly eco-friendly. Here are some answers to common questions about whether plastisol is an environmentally conscious choice

  • What is plastisol made of?

    Plastisol is made up primarily of PVC (polyvinyl chloride, made from combining electrolyzed salt water with ethylene), mixed with plasticizing agents that give it a rubbery, stretchy consistency. Traditional plasticizers were phthalate-based, but innovations in phthalate-free plasticizers allow plastisol to be made without these potentially harmful chemicals. Most formulations of plastisol will also contain heat and/or UV stabilizers, pigments, and other additives to enhance its natural characteristics.

  • How is plastisol environmentally friendly?

    While some less scrupulous plastisol manufacturers may not produce it in the most environmentally friendly ways, using it as a dip coating is very environmentally friendly, because it:

    • Produces almost no waste
    • Protects coated products, extending their lifespans
    • Is extremely low in VOCs, solvents, and other toxins
    • Is available in safer formulations
  • Does plastisol have BPA or phthalates?

    Plastisol does not contain bisphenol-A (BPA), and newer formulations of plastisol use phthalate-free plasticizers.

  • Do plastisol coatings require solvents or VOCs?

    While many plastic materials do contain volatile organic compounds (VOCs) or solvents, plastisol is extremely low on both counts.

  • Can plastisol be recycled?

    Yes, plastisol can be recycled, though opportunities to do so are limited. Individual municipalities have varying rules governing how cured or uncured plastisol can be recycled or disposed of.


Vinyl-based plastisol is one of the most versatile and cost-effective polymer coating choices, and is suitable for thick and thin protective layers applied by traditional hot dip or cold dip methods as well as molding and casting techniques. Here are answers to common questions about colors for this popular, long-lasting coating.

  • What colors can plastisol coatings be?

    While plastisol does come in a variety of stock colors, you can choose any colors for plastisol coatings to meet your project's needs. 

  • Can plastisol coatings be transparent?

    Yes, while stock colors are opaque, plastisol coatings can certainly be transparent, and range from completely clear to tinted transparent colors.

  • Are custom colors an option for plastisol?

    Yes, plastisol can be custom-colored to meet project-specific requirements, including Pantone, RAL, MIL-SPEC, and other color matching options.

  • How is plastisol colored?

    Color pigments are mixed into liquid plastisol, creating an especially consistent, even coloration throughout the coating. 

  • Can plastisol colors include special effects?

    Yes, special additives can create special effects with plastisol coatings, including:

    • Glow-in-the-dark
    • Iridescent
    • Metallic
    • Fluorescent
    • Translucent
    • Glitter
  • What colors of plastisol are best for my project?

    If you are undecided on colors, our expert team can help you choose the most appropriate colors for your plastisol coating project. Specific colors are often selected to convey specific information such as:

    • Color coding for sizes, styles, or other groupings for tools, wires, and countless other products
    • Visibility, such as bright or fluorescent colors for tool handles and safety equipment

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