Chloe Zhang
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC) and a plasticizing compound, in a liquid plasticizer. It is commonly used for coatings across many industries, from electrical and automotive to medical and aerospace. Plastisol can be applied to plastic in several ways, including screen printing/heat transfers, dip-coating, or moulding. When heated to around 180 °C (356 °F), the plastic particles absorb the plasticizer, causing them to swell and fuse together, forming a flexible, permanently plasticized solid product. This process is called 'curing'. Before being cured, plastisol flows as a liquid and can be easily poured into a mould or used for dip-coating. After curing, the plastisol becomes a flexible, rubbery consistency.
| Characteristics | Values |
|---|---|
| Composition | Colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer |
| Flexibility | Flexible and stretchable |
| Hardness | Hardening agents can be added to achieve a Shore durometer rating of up to 90 |
| Resistance | Impact-resistant and wear-resistant |
| Colour | Can be matched to any colour |
| Application | Can be applied through screen-printing, heat transfers, dip-coating, or moulding |
| Curing | Requires curing at temperatures between 180-350°F (82-176°C) |
| Thickness | Thickness can be adjusted by controlling the preheat temperature |
| Compatibility | Does not adhere to non-porous substrates such as plastic, metal, wood, and glass |
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What You'll Learn
Plastisol ink screen printing
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC) in a liquid plasticizer. Plastisol inks are the most popular inks used in the garment printing industry. They are easy to print with, do not dry in the screen, are opaque on dark garments, and adhere well to most textiles.
Plastisol inks are composed of PVC resin (a white powder) and plasticizer (a thick, clear liquid). The more plasticizer added, the more flexible the plastic becomes. Plastisol inks will not dry at room temperature and must be cured at a temperature of around 180°C (356°F) or 300-330°F (143-166°C). Curing can be done with a flash dryer, heat gun, heat press, or any oven.
When printing with plastisol ink, it is important to cure the print shortly after printing, within a minute. If curing is delayed, the plasticizer may leach into the garment, causing an oily appearance. The curing process is critical to ensuring the ink sets properly into the garment. If the ink is not fully cured, it will crack and fall apart.
Plastisol inks are ideal for printing opaque graphics on dark fabrics and can produce bright images that last for years. They are commonly used for screen printing heat transfers, which can be applied to hats, neck labels, sports apparel, and more. It is important to select the appropriate mesh for plastisol printing, such as an SBQ or Dual-Cure Emulsion, and to use recommended additives to avoid upsetting the chemical balance and impacting the curing process.
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Plastisol dip coating
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer. It is a popular plastic coating material due to its durability, impact resistance, and ability to resist abrasions and other damage. Plastisol dip coating is a simple, cost-effective process with minimal waste, making it a top choice for coatings.
The dip coating process involves preheating the object to be coated, fully or partially dipping it into a liquid tank of PVC, and then curing it in a heated chamber. The heat causes the plastisol to fuse, forming a tough, homogeneous mass. The hotter the mold and the longer the dip, the thicker the gelled coating.
Additionally, plastisol dip coating can be used for creating complex shapes. The plastisol follows the details of the mandrel or mold exactly, allowing for precise parts and intricate designs. The surface appearance can vary from shiny to matte, depending on the mold's texture.
Plastisol is also commonly used in molding processes, where it is poured or injected into molds and then cured. This application is suitable for creating various products, such as furniture feet, spacers, washers, plugs, and fishing lures.
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Plastisol slush moulding
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer. It is commonly used for coatings, particularly outdoor applications like roofs and furniture, and grips for tools. Plastisol is also used for slush moulding, a form of spin casting that is more complex than simple resin casting but less expensive and less sophisticated than injection moulding.
Slush moulding is a technique used to produce flexible and semi-rigid mouldings with a detailed surface finish on the outside of the moulding. It involves filling a hollow female mould or tool with liquid material to a predetermined level, then curing it to achieve the desired wall thickness. The remaining liquid material is then poured out, and the tool is cooled before the finished moulding is removed.
The slush moulding process for plastisol specifically involves filling a cavity or hollow mould with liquid plastisol and exposing it to heat, causing the plastisol to gel and fuse to the mould. The mould is then inverted, and the excess liquid plastisol is poured out. Additional heat is applied to cure the plastisol for proper fusion. Finally, the mould is cooled, and the finished moulded plastisol part is removed.
This process allows for a uniform wall thickness in the finished part. The moulds can be made of fabricated steel, cast, or machined aluminium, and they can produce an unlimited number of castings. Slush moulding is well-suited for high-speed commercial operations, as the ovens used to gel and fuse the plastisol coatings can accommodate a wide range of mould sizes and designs.
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Plastisol heat curing
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer. Plastisol inks will not dry and must be cured. The curing process involves heating the substance to a very high temperature, causing a chemical reaction that makes the fibres bind to the ink.
There are several methods for curing plastisol, including using a flash dryer, an oven, or a heat press. When using a heat press, set the temperature 20-30 degrees above the curing temperature of the ink, which is typically around 180 degrees Celsius (350 Fahrenheit). Use light to medium pressure and place a heat-resistant non-stick sheet, such as Teflon, on top of the design. Press for 10-20 seconds, then remove the sheet and the shirt. Test the shirt by stretching it at the design—if it doesn't crack, the ink is cured.
For curing plastisol ink on a cotton shirt, or other fabrics that are difficult to print on with higher temperatures, consider using a low-cure plastisol ink that cures at a lower temperature, typically around 275-280 degrees Fahrenheit. This will prevent scorching or dye migration.
Another method for curing plastisol is through screen printing, which involves heating the ink enough so that it adheres to the fibres of the fabric. This method can be used on a variety of materials, including shirts, sports equipment, and glasses. However, it is important to note that curing with a heat gun can be challenging for larger prints, as it is difficult to maintain consistent heat across the entire print.
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Plastisol spray coating
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer. It is a popular vinyl-based plastic coating with applications across many industries, including electrical, automotive, medical, and aerospace. It is known for its flexibility, high resistance, and cost-effectiveness.
When heated to around 180°C (356°F), the plastic particles absorb the plasticizer, causing them to swell and fuse together, forming a viscous gel. This process is called "curing." Once cured, Plastisol has a flexible, rubbery consistency and can be used for a variety of applications.
One method of applying Plastisol to plastic is through spray coating. Spray coating involves spraying the Plastisol liquid onto the desired surface. The thickness of the coating can be adjusted by controlling the temperature and coating speed. Spray coating is suitable for items that require a lesser degree of corrosion or chemical resistance, as it typically results in a thinner coating compared to dip coating.
To achieve effective spray coating, several factors need to be considered. Firstly, the Plastisol liquid should be properly prepared by mixing the PVC particles with the appropriate amount of plasticizer to achieve the desired viscosity. Secondly, the surface to be coated should be adequately heated and prepared to ensure proper adhesion of the Plastisol. This may involve sanding or priming the surface.
Additionally, the temperature and coating speed should be carefully controlled to attain the desired thickness. Multiple coats of Plastisol can be applied to achieve greater thickness and ensure even coverage. It is also important to allow for proper curing between each coat. Curing can be achieved by using a flash dryer or an oven, with temperatures reaching about 180°C (350°F) for full curing.
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Frequently asked questions
Plastisol is a colloidal dispersion of small polymer particles, usually polyvinyl chloride (PVC), in a liquid plasticizer.
Plastisol is cost-effective, flexible, highly resistant, and durable. It is also versatile and can be used in a range of products, including outdoor furniture and automotive applications.
Plastisol can be applied to plastic through screen-printing/heat transfers, dip-coating, or molding. The product is first preheated in an oven and then lowered into the Plastisol solution.
Curing can be done with a flash dryer or any oven. Most plastisols need to reach a temperature of about 180 degrees Celsius (350 Fahrenheit) to cure fully.
Plastisol is commonly used for coatings, particularly in outdoor applications (roofs, furniture) or grips for tools. It is also used for screen printing onto textiles and for slush molding or slush casting.
