Overview

Cast to Last: Flexible, Durable, Precise.

Plastisol casting is a flexible and cost-effective manufacturing process used to produce durable parts with high detail and consistency. This method involves pouring liquid plastisol—a suspension of PVC resin and plasticizer—into open or closed molds, then heat-curing it to form seamless, fully molded components. The process is ideal for creating flexible, complex parts that require precision and long-lasting performance.

Formulations can be tailored to meet specific requirements, including viscosity, cure profile, hardness, color, and surface texture. Engineered for excellent flow and detail replication, plastisol ensures complete filling of intricate mold designs, resulting in uniform, high-quality parts. This makes plastisol casting a reliable solution for custom components across industrial, medical, automotive, and consumer product applications.

Plastisol - Casting Series

Features

Versatile Applications – Commonly used for grips, coatings, medical parts, toys, and industrial components.
Highly Customizable Formulations – Adjustable viscosity, color, texture, and hardness to meet specific needs.
Efficient for Low to Medium Volumes – Ideal for producing durable, detailed parts without the high cost of large-scale tooling.
Enhanced Performance Options – Additives available for improved chemical resistance, abrasion durability, UV stability, and softness.

PVC film plastic film or foil, isolated on white background

Rolled black protective door mat on a white background

Fatigue and Switch Mats – Rollcoating and Closed Mold Casting

Hot Melt Plastisols – Injection and Pour Casting

Downloads

Download all files associated with our Plastisol casting series.

Download Plastisol Casting Sales Sheet

Document file size 843.25 KB

Technical Properties

Below are some key technical properties of our Plastisol casting series. For full specifications and performance details, please contact us to request the technical data sheet.

Hardness

Shore A to Shore D

Resistance

Flame / UV / Mildew / Chemical / Impact

Physical

Tensile / Tear / Elongation / Density

Colors

Pantone / RAL / AMS STD 595

Compliance

Non-phthalate / Prop 65 / REACH / ROHS / FDA / UL

Applications

Plastisol casting is a versatile process where liquid plastisol is applied to a release liner, permanent substrate, or casting belt, then fused to form a flexible, durable layer. Used to create products like walk-on mats, car mats, cast films, and sound-dampening barriers, this method allows for custom textures, thicknesses, and performance properties across a wide range of industrial and commercial applications.

Protective Films & Skins

Cast film

Material Handling & Impact Protection

Dunnage, trays, bumpers

Flooring & Safety Surfaces

Walk-on mats, fatigue mats, car mats

Acoustic Insulation

Sound-dampening barriers

Solutions

Explore Our Plastisol Casting Solutions: Our vinyl-based plastisol compounds are designed for casting flexible, durable parts with precise detail. Customizable in viscosity, hardness, cure profile, color, and texture, they’re ideal for low to medium-volume production. From industrial to consumer applications, we can help you find or develop the right solution for your needs.