Plastisol molding produces flexible parts that are used as covers or coating. The process requires a metal mold capable of withstanding the 300 to 400 degree F molding temperatures and liquid plastisol. Plastisol is a solution of powdered polyvinyl chloride (PVC) and plasticizer. The mold is preheated to 350 degrees F. It is then dipped into (for as in dip molding) or filled with (for open slush molding) plastisol. The heat from the mold moves into the plastisol heating and swelling the PVC particles. The mold remains in contact with the liquid Plastisol until the heats penetrates to 1/16 or 1/8" depth. The heated PVC particles swell, absorb the plasticizer, and then come in contact with each other. From there, the dip mold is then removed from the plastisol. In slush molding the excess Plastisol is poured out of the mold. The coating on the surface remains. The thickness of the coating is determined by the amount of time the mold stays in contact with the liquid plastisol. The mold is then reheated to 350 degrees F. The reheating fuses the PVC particles together and forces off any excess plasticizer converting the remaining plastisol into an homogenous mass. Note that I said homogenous. Sounds proffessional doesn't it?

The ratio of PVC to plasticizer determines the hardness of the coating. Rigid plastisol coating has PVC to plasticizer ratios of 100 part of PVC to 25 parts plasticizer. which results in Shore A hardness readings (Rockwell Hardness Test) of 8. Plastisol with 1:5 ratios are much softer, with Shore A hardness reading of 98. Plastisols are also used in rotational molding, spray coatings. Common dip molded products are: gloves, tool handle coatings, lip on grips, cushioning for kitchen implements, covering for sharp objects, insulation and the oval shaped coin purses. Common slush molded products are arm rests, head rests, road safety cones, doll parts, and toys. The resiliency of plastisol parts is seen kitchen gloves which can be pulled and stretched without tearing and returned to their original shape.