Developing a new product for your company isn’t necessarily as difficult as it might seem. At Piper Plastics, we know that product development might feel like a tough task to conquer, but the truth is that by utilizing our plastisol dip molding and plastisol dip coating processes, you can create new products and perfect them in a relatively short amount of time.
Just bring your sketches or ideas to us, and we can tell you more about how processes like PVC dip coating can be used to bring your new product to life.
- When you come to us with an idea, we’ll begin by choosing an appropriate thermoplastic processing technique, and developing CAD drawings of your design.
- Next, we’ll create a prototype of your new product using plastisol dip molding or plastisol dip coating.
Plastisol dip molding involves creating a dipping mandrel based on your design, and then dipping it into plastisol to create molds of your product. Plastisol dip coating, on the other hand, involves using your sample parts as the mandrel and coating them with sample coats. Both options are very inexpensive and will allow you to test different materials, colors and more.
Check out the video below and contact us at (800) 966-9919 with any product development questions you might still have.
If you’ve ever wondered how to get an idea in your mind transformed into an actual product, this video describes the process we use at Piper Plastics to help you do just that.
It all starts with an idea. All we need is a description, a quick sketch or a product to duplicate to get started.
Using our expertise in thermoplastic processing techniques, we will review your requirements for a potential fit with our in-house dip molding, dip-coating, or fluidized bed processes. If there isn’t a fit, we’ll offer recommendations. If there is a fit, we move on to the next step… design.
Using your initial requirements, we’ll work with you to reduce them to a design that both functions for you and can be reasonably made by us.
This step usually requires some CAD drawings and specification to be made. Once the design is approved, we can move on to the prototyping phase.
During the prototyping phase of a dip molding project, a dipping mandrel needs to be made; however, if it’s a dip coating project, we’ll ask for a few of your parts to sample coat. Making the prototype mandrel is usually an inexpensive proposition, and we will either make it ourselves or use one of our approved vendors. With that prototype mandrel, or your sample parts, we will mold or coat in various materials, colors, textures, and thicknesses. Working together with you, we will continue to make refinements until you are satisfied with the product.
Moving to production is straight forward, as we work with you to determine the best way to tool up based upon your expected volumes and budget. Once in production, we continuously monitor our relationship with you, using our ISO certified quality system.
Materials We Process
At Piper Plastics Corp., we process Polyvinyl Chloride and Nylon using different methods.
By far, the material that we process the most is Plastisol. Plastisol is a thermoplastic liquid at room temperature and is primarily composed of PVC suspension resin and plasticizer. When processed correctly using heat, the plasticizer, which makes the vinyl flexible, gets locked into the Vinyl molecules and the cooled part becomes a solid. Additional ingredients can be added to the formulations to add color, add antimicrobials, add texture, and impart various other characteristic to the finished products. Plastisol is used in all sorts of products, from plier handles to nasal cannula, bottle openers and heart catheters.
Another form of PVC that Piper processes is fluidized bed PVC powder. This is the same material as plastisol, however instead of being a liquid initially, it’s a fine powder. Utilizing a fluid bed, which blows air up through the powder, we can dip metal parts and create beautiful and colorful coatings. Familiar products that have been dipped using PVC powder in fluid bed include point-of-purchase displays, bagel baskets, military items and wristwatch display cuffs.
Finally, we also process Nylon powder at Piper. Utilizing the same fluid process as the PVC powder, we are able to apply Nylon to our customer’s products. Nylon is a thermoplastic that is much harder than and has a lower coefficient of friction than PVC.
Unfortunately, Nylon cost more than PVC, however there are times when it’s worth it because the physical properties of Nylon are needed for a particular application. A great example of a fluid bed nylon product is the basket for the blood pressure cuff you find in your doctor’s office.