Information about plastic coatings and dip molding with a list of leading manufacturers.
Plastic coating involves the application of liquid polymers or plastics onto a component using methods such as dipping or immersion. This technique forms a strong plastic layer that provides both protection and visual appeal. It significantly enhances the material's resilience against scratches, abrasions, corrosion, and environmental wear. By reinforcing metal parts, plastic coatings extend their operational life. Furthermore, these coatings deliver practical advantages like enhanced grip and user insulation.
Plastic coatings are prevalent on hand tools, grips, and handles. As an example, pliers typically come with plastic-coated handles that elevate user convenience and improve handling by making the tool more comfortable to use and durable. This type of coating also benefits a multitude of other products by offering extra strength and protection, such as shopping carts, baskets, forceps, covers, caps, plugs, and numerous other items.
Plastic coatings serve effectively as thermal and electrical insulators. They are often applied to hand tools like tongs and spatulas to ensure safety when dealing with hot objects. These coatings are also essential in the electronics sector, insulating components like wires, cables, and digital meter probes.
The method of attaching a plastic coating to an existing metal item is referred to as dip molding. During this process, the metal component acts as a mold for the polymer. The component is initially treated and warmed before being submerged in a liquid polymer. The polymer adheres to the metal and solidifies as it cools, resulting in a durable plastic layer.
Dip molding resembles dip coating but includes an added phase for extracting the molded part. This approach produces single, hollow, and double-walled components, reducing the requirement for additional processes like trimming or deflashing. By limiting these subsequent stages, dip molding conserves materials. Examples of dip molded goods include latex gloves, accessories, cups, plastic caps, and components used in sports equipment.
The selection of polymers for coating and molding processes is crucial for ensuring optimal product durability, finish, and performance. Common polymers used for coating applications and dip molding include plastisol, latex, neoprene, polyurethane, and epoxy. These polymers, also referred to as thermoplastic and thermosetting resins, offer distinct advantages based on their chemical properties and suitability for industrial applications. An important feature of these polymer solutions is that they remain in a liquid or semi-liquid state at room temperature, enabling easy handling and manufacturing without requiring extensive pre-processing or heating. Additionally, to ensure effective dip coating and dip molding, the liquid polymer must possess a sufficient viscosity and appropriate surface tension to adhere evenly to the mold or substrate. These properties prevent the polymer from dripping or sagging, which ensures a uniform coating thickness until the material sets and cures—an essential requirement for achieving high-quality, defect-free finishes in industrial, automotive, and consumer product manufacturing.
Plastisol is a widely used polymer in both dip molding and dip coating applications. It consists of finely ground polyvinyl chloride (PVC) resins suspended in a liquid plasticizer, forming a stable and versatile compound. Upon heating, plastisol undergoes a physical transformation to become a soft, flexible material with a rubber-like texture as it cools and solidifies. Plastisol is renowned for its durability, resistance to corrosion, abrasion resistance, and impact strength. Its non-conductive nature and high dielectric properties make it a preferred choice for electrical insulation and protective coatings within the electronics and automotive industries. Colorants or additives can be incorporated to achieve custom finishes, improved UV resistance, or specific textures, making plastisol ideal for producing protective tool grips, PVC caps, handles, and custom medical components. Manufacturers value plastisol for its processability, cost efficiency, and ability to produce consistent, high-quality molded parts in a wide range of industries.
Latex is a water-based dispersion of tiny polymer particles, primarily comprised of rubber, and serves as a foundational material for manufacturing both natural and synthetic rubber products. Latex coatings and molded items are favored for their elasticity, high tear resistance, and versatility across medical, laboratory, and industrial settings. Examples include latex gloves, balloons, tubing, and rubberized coatings. While latex is widely accessible and safe for the majority of users, it's important to address latex allergies—these are typically triggered when the latex degrades into fine particles or powder, leading to the introduction of alternative polymers such as nitrile and neoprene in sensitive environments. As a result, industries seeking hypoallergenic solutions are increasingly shifting towards synthetic materials. Despite these concerns, latex continues to play a critical role in applications demanding high flexibility, puncture resistance, and tactile sensitivity.
Neoprene, created through the polymerization of chloroprene, serves as a high-performance alternative to latex in the dip molding industry. This synthetic rubber is recognized for its chemical resistance and impressive flexibility, maintaining its mechanical properties in a wide range of temperatures. Neoprene’s robust resistance to oils, solvents, flame, and weathering makes it a preferred material in automotive components, expansion joints, bellows, protective sleeves, gaskets, and even medical devices. Thanks to its resilience and non-allergenic profile, neoprene is frequently selected for projects where both safety and durability are top priorities, further supporting its widespread use in industrial coating and custom molding applications.
Polyurethane is a unique polymer containing urethane groups linked via carbamate bonds. Praised for its broad chemical compatibility, abrasion resistance, flexibility, and outstanding resistance to deformation and fatigue, polyurethane is widely applied in medical tubing, balloon catheters, flexible hoses, automotive seals, and industrial liners. In coating and molding processes, polyurethane’s customizable properties allow for the production of both rigid and flexible products, making it ideal for protective coatings, wear-resistant surfaces, and impact-absorbing applications. Manufacturers benefit from polyurethane’s rapid curing capability, high transparency, and exceptional toughness, ensuring reliable performance in challenging operating environments and extending product life.
Epoxy is a versatile thermosetting polymer renowned for its exceptional adhesion, mechanical strength, chemical resistance, and heat tolerance. Upon mixing and curing, the molecular chains form a dense, cross-linked structure, resulting in a hard, stable coating that provides long-term protection against corrosion and harsh environments. Epoxy coatings are widely used for electrical insulation, industrial equipment, automotive parts, pipe protection, and aerospace components due to their reliability and strong barrier properties. In dip molding and coating, epoxy ensures smooth finishes, increases product longevity, and meets stringent regulatory requirements for safety and performance. As a result, epoxy is a popular choice for manufacturers seeking superior surface protection and structural integrity in specialized applications.
Choosing the right polymer for coating or molding depends on several critical factors including desired product properties, process temperatures, chemical compatibility, physical performance, regulatory standards, and environmental exposure. Assess the intended application—whether it’s for electrical insulation, corrosion protection, medical devices, or impact resistance—to determine the most appropriate material. Evaluate considerations such as cost, availability, processability (viscosity and cure rates), and the potential for customization with additives or colorants. Manufacturers often consult technical datasheets and collaborate with polymer suppliers to find solutions tailored to their unique application requirements.
For detailed product comparisons and in-depth technical support, contact leading coating and molding polymer suppliers for expert advice, material samples, custom formulation options, and current pricing information. This ensures your selected polymer solution delivers optimal performance, safety, and compliance for your specific project needs.
As discussed earlier, dip coating and dip molding share a similar operational principle. This chapter provides a comprehensive overview of the entire production process for plastic coatings, with a detailed look at both dip coating and dip molding procedures used to apply durable plastic layers to metal and other substrate materials.
Pre-treatment is a critical step in the successful application of plastic coatings onto metal substrates and other surfaces. Proper pre-treatment ensures optimal surface preparation, maximized adhesion, improved corrosion resistance, and enhanced long-term performance for both dip coating and dip molding techniques. By focusing on effective surface preparation, manufacturers can increase the lifespan of products and lower maintenance costs, while meeting demanding industry specifications for coated parts.
In dip coating, the pre-treatment process is particularly detailed compared to dip molding because the polymer coating must adhere permanently to the metal substrate, which also acts as the mold. Below, we outline each essential pre-treatment step for achieving a high-quality, industrial-grade plastic coating on various components and assemblies.
The presence of surface contaminants—such as dust, oils, oxides, or other impurities—can disrupt the molecular bonding between polymer coatings and the substrate, creating weak points prone to premature failure. Rigorous cleaning and surface treatment protocols are essential to ensure polymer coatings are free from defects and are able to deliver superior protection in harsh environments.
Residual oils, cutting fluids, and greases on the metal substrate surface serve as common sources of contamination. Failure to remove these residues can reduce both the water resistance and mechanical bonding strength of applied plastic coatings—potentially leading to delamination, blistering, and coating failure over time. Standard degreasing methods include alkali or acidic washes, ultrasonic cleaning, and thermal degreasing, each tailored for the specific substrate material and level of contamination involved.
For re-coating operations or repair works, it is crucial to remove existing coatings completely before applying a new plastic layer. Proper stripping techniques ensure thorough substrate exposure and readiness for subsequent pre-treatment stages, such as surface activation or roughening, which are vital for maximizing new coating adhesion.
Beyond simple cleaning, surface modification adds desirable properties to substrates prior to plastic coating application. These enhancements are designed to improve not just the coating process, but also the material’s in-service properties (e.g., wear resistance, antimicrobial capability, and electrical insulation) and market performance in demanding industries such as automotive, medical devices, and consumer appliances.
Phosphating—or phosphate conversion coating—involves the application of a uniform phosphate layer to the substrate surface before plastic coating. This conversion coating process greatly enhances corrosion protection, serving as a primer that prevents rust and oxidation even if the polymer coating is later damaged. Common phosphate systems used in dip coating applications include zinc phosphate, iron phosphate, and tricationic phosphate—each offering unique benefits for adhesion promotion and surface passivation.
Shot peening bombards the substrate surface with small spherical media, inducing compressive residual stress layers that strengthen the material, reduce the likelihood of brittle fracture, and help resist crack propagation. Shot peening has become an industry-standard process, especially when manufacturing high-reliability parts exposed to cyclic or mechanical stresses.
Media blasting—such as sandblasting, glass bead blasting, or metal grit blasting—further alters and roughens the substrate surface, dramatically increasing its surface area for adhesive bonding. This process improves the wettability of primers, undercoats, and polymers, leading to stronger physical and chemical bonds. Surface texture optimization via blasting is frequently employed for plastic coating technologies seeking to maximize the longevity and integrity of protective polymer layers.
De-embrittlement is a post-treatment step that eliminates hydrogen embrittlement—a potentially catastrophic phenomenon in high-strength steel substrates—by diffusively removing absorbed hydrogen through controlled heat treatment. This step is necessary when acidic treatments or phosphate applications might lead to hydrogen uptake, ensuring that plastic-coated components offer maximum safety and reliability for industrial, automotive, or structural use.
After modifying the substrate, several additional pre-treatment stages focus on enhancing the coating’s performance, durability, and appearance for end users:
Specialized primers serve as anchor layers, chemically bonding the substrate to the primary polymer coating. Selecting the right primer formulation further boosts chemical, environmental, and abrasion resistance, extending the usable life of dip-coated and dip-molded products in various industries—including electronics, plumbing, and agriculture.
Undercoats, or secondary layers, impart critical physical properties such as enhanced UV stability, scratch resistance, color uniformity, or antistatic characteristics to the finished product. While undercoats alone do not serve as the main coating, they are engineered to synergize with top-layer polymer coatings, optimizing both aesthetics and functional performance. In dip molding, mold release agents such as silicone and polytetrafluoroethylene (PTFE) are crucial for facilitating part removal and achieving defect-free molded surfaces.
After completing all pre-treatment processes, thorough drying of the mold or substrate—often in a controlled environment—is essential. Trapped moisture can expand during heating, risking the formation of voids, blisters, or bubbles that can compromise the structural and visual quality of the final plastic coating.
The mold is uniformly pre-heated in an industrial oven to a specific target temperature, determined by the requirements of the plastic coating process and desired coating thickness. Precise temperature control and even heat distribution, influenced by mold geometry and oven air circulation, are fundamental to achieving uniform coatings without thin spots or defects, especially critical in high-precision or safety-critical applications.
Once pre-heated, the mold is partially or fully submerged in a liquid polymer bath—or introduced into a fluidized bed for powder coating—depending on the specific manufacturing technology used. The outer mold dimensions dictate the finished part’s internal shape, enabling high repeatability in components such as tool handles, grips, and caps. The immersion time (dwell time) directly affects plastic coating thickness; industries often leverage extended dwell times for enhanced protection or customized finish requirements. Both immersion and withdrawal rates are carefully optimized to prevent surface irregularities and maintain material efficiency.
Manufacturers frequently employ advanced process controls to monitor and adjust dipping speeds, withdrawal velocities, and bath temperatures, ensuring best-in-class coating finishes. In the context of powder-based fluidized bed coating, polymer powder particles are melted and fused onto the hot mold, creating thick, seamless, and wear-resistant coatings ideal for heavy-duty industries and high-corrosion environments.
Following dip coating, excess polymer is drained off the mold surface—either by gravity or assisted mechanisms—to achieve the required film thickness. Multiple dip cycles or specialized formulations may be used to build up additional thickness for demanding applications, such as chemical storage vessels, outdoor enclosures, or electrical insulators that must withstand aggressive operational environments.
The coated part is transferred to a curing oven, where the polymer is thermally set. This crucial step removes all residual solvents and moisture, finalizes the polymer’s mechanical properties (e.g., elasticity, hardness, and flexibility), and, for thermosetting polymers, enables the completion of chemical cross-linking. Curing transforms the polymer coating into a durable, continuous film with enhanced resistance to mechanical abuse, chemicals, and UV radiation.
After curing, the coated part is cooled to ambient temperature to lock in the newly acquired properties. Cooling methods include water quenching—beneficial for rapid production cycles—or air convection, either natural or forced, to prevent thermal shock. Proper cooling is critical for maintaining dimensional stability, minimizing stress cracking, and achieving flawless, high-gloss finishes desired in many commercial and industrial markets.
Once the coating has fully set, the coated components are carefully removed from the molds. In dip molding, this demolding process can be manual or mechanically automated, especially for high-throughput manufacturing lines. The process yields precise, seamless, and aesthetically pleasing plastic-coated components, ready for use in packaging, automotive, medical, industrial, and consumer products.
The dip molded plastic components—or plastic coatings—often undergo secondary finishing processes such as notching, punching, pad printing, and decorative enhancements. These value-added steps allow manufacturers to tailor both the appearance and function of plastic-coated parts to unique customer or industry requirements, further expanding the range of end-use applications for dip-molded and dip-coated products.
Dip coating and dip molding processes share similar machinery. In a dip coating or dip molding operation, several machines and components are used to produce dip molded plastic.
Dip molding is an alternative to traditional molding. Parts are seamless and made using inexpensive tooling, which makes the process ideal for cost effective prototyping. The process for dip molding is similar to candle making. A heated metal mold is dipped into a tank of liquid material, which can be a form of plastic or rubber.
The material in the tank may be completely melted or be at ambient temperature. The mold remains in the dipping tank for varying times depending on the required thickness of the molded product. Once a sufficient amount of time has passed, the molded product is removed from the tank, cured, and stripped from the mold.
As with the manufacture of candles, the metal mold for dip molding may be dipped several times to increase the number of layers of the molded product. In addition, the mold may be dipped in different materials to create varying effects. Handles for tools may be dipped in a hard plastic to create a tight fit and durability. They may then be dipped in a softer material to form a comfortable grip.
Unlike dip coating, where the material remains attached, dip molded products are demolded during the final step of the molding process. Dip molding produces single wall, hollow, and double wall products, which eliminates the need for trimming and deburring. Gloves, clothing, cups, lids, and equipment and parts are produced using dip molding.
The dip molding process includes the use of:
A key factor in regard to dip molding is following the steps of the process to ensure the quality of the final molded product. Each step, from dipping to finishing, is adhered to such that the desired shape is achieved.
Finishing - As with the design of all dipped molded products, finishing improves the appearance of a product and involves the use of different processes that can include coatings and washing, each of which makes it easier to work with a product.
Rotary-type configuration - Several mechanical arms equipped with carrier frames are mounted on a rotating wheel, similar to a carousel. As the wheel turns, each arm is indexed to dip the mandrels into different depths of the solution.
The dip molding process is restricted to plastics or rubbers that form well around the mandrel under high temperatures. The most commonly used dip molding material is polyvinyl chloride (PVC), due to its affordability and ease of use. Other types of materials are various thermoplastics including polythene, polypropylene, polystyrene, polyamide and polycarbonate. Also available are natural latex rubber, neoprene, nitrile (Buna-n), and silicone, which are processed in a similar manner as plastics but require different types of curing and heating treatments.
Dip molding manufacturers provide their customers with an array of material choices for the forming of their products. Although plastic is a popular choice, various forms of rubber are ideal and provide highly durable and flexible products.
The choice of a polymer for the dip molding process involves ones that are available in liquid form without the need for additional processing. Polymers considered have sufficient viscosity to prevent run off.
Although the materials listed above are commonly used for dip molding, there is a long list of varying materials used for the process. Each type of material requires some form of accommodation in order to be adapted to dip molding.
Plastic coating machines play a crucial role in modern industries by applying protective, insulating, or decorative plastic layers to a variety of products. This enhances their durability, functionality, and appearance across sectors such as manufacturing, construction, automotive, and electronics. Below, we explore several top brands of plastic coating machines available in the United States and Canada, highlighting specific models and their distinctive features, functions, and capabilities:
Features: The Nordson Encore LT is a manual powder coating system engineered for precision and efficiency in plastic coating. Its user-friendly operation and control make it ideal for small to medium-sized applications. The system utilizes advanced electrostatic technology to ensure a consistent, high-quality finish and includes a lightweight, ergonomic gun design for ease of use. The Encore LT also supports rapid color changes and promotes effective powder utilization.
Features: The WAGNER PEM-X1 is a manual liquid coating system known for its precision and dependability in plastic coating applications. It provides adjustable coating parameters to accommodate a range of needs. The system is equipped with advanced atomization technology for a smooth and consistent coating distribution. Its user-friendly control panel offers intuitive settings and monitoring options. The PEM-X1 also facilitates quick material changes and simplifies maintenance.
Features: The Reliant Finishing Systems PC601 is a conveyorized powder coating system tailored for high-volume applications. It provides a continuous coating process with efficient use of materials. The system boasts a sturdy conveyor for smooth and consistent movement of parts and employs advanced powder application technology for even and durable coatings. Additionally, the PC601 features automated controls and customizable options to maximize productivity.
Features: Graco provides a range of electrostatic liquid coating systems designed for plastic coating tasks. These systems deliver efficient, high-quality finishes with excellent transfer efficiency. They incorporate advanced electrostatic technology to ensure even coverage and minimize overspray. Users benefit from precise control over coating parameters such as flow rate and atomization. Graco's electrostatic liquid coating systems are recognized for their reliability, durability, and user-friendly operation.
Features: The Dymax UVC-6 is a conveyor system engineered for UV-curable plastic coating applications. It provides precise control over UV exposure and curing times, ensuring effective coating performance. The system includes multiple lamp heads to guarantee even and complete curing. It also features adjustable conveyor speed and height for added flexibility and customization. The UVC-6 is compatible with other Dymax equipment and offers user-friendly controls.
Note that model availability and features may change over time. For the most current information on models that meet your needs, please contact the manufacturers or their authorized distributors.
Dip coating and dip molding offer several advantages to manufacturers, thanks to their straightforward concepts and versatile applications. Here are some key benefits of using these methods:
These processes do not result in shrinkage, allowing for precise achievement of the desired internal dimensions. Additionally, unlike other molding methods, the cooling rate is less critical and does not require stringent control.
Dip coating and dip molding effectively create seamless, double-walled components. Unlike parts joined from multiple pieces, which can have stress points at the seams that compromise durability, these methods ensure a continuous and robust construction.
Dip plastic casting allows for the production of large plastic components by encapsulating sizable metal pieces through dip molding. Producing similar large plastic parts using injection or blow molding would necessitate large tooling and become a costly process. The primary constraints of dip molding are the dimensions of the tool, the capacity of the pre-heat and curing ovens, and the size of the polymer solution tank.
Additionally, dip coating and dip molding are capable of creating intricate designs with severe undercuts and angles.
Designers can easily add extra details to the final product, as the tooling material can be readily modified. Additionally, different coating materials and thicknesses can be achieved using the same tooling by adjusting the formulation of the polymer solution.
Dip coating and dip molding are well-suited for short runs and laboratory-scale production due to their straightforward equipment requirements. Unlike injection and blow molding, which necessitate complex machinery and extensive floor space, these processes involve simpler setups. Additionally, the tooling for dip molding is cost-effective as it does not require high pressures to operate.
In dip coating and dip molding, excess solution drains back into the dipping tank, making it possible to reuse it. This is in contrast to other molding methods, where excess polymer material often results in cut-outs and runners that need additional processing for recycling. Dip coating also offers advantages over spray coating, as some of the spray material typically ends up on the walls of the coating chamber or equipment, leading to waste.
However, there are limitations to these processes where other molding methods may offer advantages. The following are some of the disadvantages:
While the internal dimensions achieved with dip coating and dip molding are precise, obtaining an exact coating thickness can be challenging. This is because it depends on various factors, including dwell time, tooling temperature, immersion rate, withdrawal speed from the polymer solution, and the properties of the polymer solution itself. These variables can also make it difficult to achieve uniform coating thickness distribution.
Dip molding is a time-consuming process due to the extended heating, dipping, and cooling cycles required.
Plastic coatings have become an integral part of manufacturing, used to enhance the appearance and functionality of cars, tools, appliances, sports equipment, and handrails. Their adaptability and versatility make plastic coatings a valuable addition to a wide range of products. In today’s market, plastic coatings are essential for ensuring the longevity and durability of both commercial and industrial items.
The demand for plastic coatings can be summed up in three key attributes: longevity, durability, and safety. Modern producers are continually seeking methods to extend product life while ensuring safety and reliability. These critical factors drive the development of new products, influencing every
Years ago, customers expected that new products would eventually need replacement, a principle that manufacturers relied on to sustain their market share. However, with technological advancements and the increasing complexity and cost of products, consumer expectations have shifted towards durability and long-term performance. In response, manufacturers have developed techniques to extend the lifespan of their products.
As component design and capabilities have advanced, a range of exceptionally strong plastic polymers has been developed to suit the needs of modern devices. These polymers contribute significantly to the longevity of electronics, such as televisions and computers, by providing unmatched durability under challenging conditions. When used as coatings, these polymers create a protective layer around commercial and industrial tools, enhancing their durability and extending their useful life.
In both commercial and residential settings, protective coatings are essential to prevent injuries from uncovered corners or exposed edges. In industrial environments, where tools can be complex and hazardous, plastic coatings play a crucial role in safeguarding workers from dangerous materials and equipment. Plastic-coated safety walls, gates, and enclosures act as shields, providing crucial protection and reducing the risk of harm.
Moreover, plastic-coated tools offer several benefits when used with moving parts, electrical circuits, and controls. Ensuring worker safety is a core principle of modern manufacturing, and plastic coatings contribute significantly to this goal by enhancing the safety and functionality of tools and equipment.
Vibrations are an inherent byproduct of operating heavy machinery and industrial equipment. To ensure the longevity of their products, facilities work diligently to minimize and manage these vibrations. A key component of this effort involves using plastic coatings, which help to prevent direct contact between machinery parts and reduce overall vibration.
Despite numerous efforts to reduce noise in production environments, it remains a significant aspect of manufacturing due to the high forces involved in producing large quantities of products. In addition to addressing vibrations, plastic coatings are also employed to mitigate noise. They are used in various applications such as separators, gaskets, shields, controls, and enclosures to help dampen and control sound levels.
Reducing friction in industrial processes enhances efficiency and ensures smoother operation across various production tasks. Friction can cause equipment wear, abrasions, and electromagnetic interference (EMIs), all of which can be detrimental to machinery. Applying plastic coatings to different components significantly lowers friction, thereby improving safety and boosting productivity.
Modern industrial machinery often includes insulation to safeguard both workers and products. Plastic coatings are commonly used due to their durability, ease of application, and long-lasting performance. These coatings help to reduce electromagnetic fields (EMFs), prevent direct contact between metal components, and ensure the smooth operation of equipment.
Applying protective plastic coatings provides additional protection and value to industrial processes. This investment helps reduce wear, damage, and the need for frequent replacement of critical machinery, while also significantly enhancing worker safety.
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