Summary of Plastisol’s History
Plastisol products and dip coatings would not have been possible without the development of Polyvinyl Chloride in Germany about 1910.
In the 1920’s researchers were looking for a substitute for relatively scarce natural rubber then used in tire manufacturing. The result was plasticized polyvinyl chloride, or what we refer to today as PVC.
In the 1930’s other automotive uses for PVC were developed including shock absorber seals.
Plastisol is a solution of PVC resin in a liquid plasticizer, (a plasticizer is an additive to plastic resins that make them more flexible, workable, or improve their ability to stretch, or to be molded and thermally cured to hold a desired shape.)
During World War II Plastisol replaced unavailable natural rubber as a wire insulation material. It provided molded covers for shock absorbers on military aircraft and a protective and comfortable material for covering hand tool grips such as pliers and cutters. There are many other applications.
When Industry returned to civilian production at the end of the war it was of course natural that Plastisol continued to be used and was adapted to civilian products. It’s use has grown dramatically in the intervening 60 plus years since.
Dip Molding and Dip Coated Plastisol products have grown in use, and have remained so popular because they provide a cost effective and durable solution for many commercial, industrial and consumer products.
Dip Molded plastic parts are a great alternative to injection molded parts produced for many applications with much less of the initial set-up costs.
An in Depth Look at the History of Plastisol and PVC
PVC, or polyvinyl chloride, is one of the most versatile and widely produced plastics in the world. Its development in the early 20th century laid the foundation for the invention of plastisol—a liquid form of PVC that would go on to revolutionize coating, molding, and printing technologies across countless industries. At Carlisle Plastics Company, our extensive experience in this material begins with an understanding of its history and evolution.
The Early Development of PVC
Vinyl chloride, the chemical building block of PVC, was first polymerized in the late 1800s. However, early forms of PVC were brittle and difficult to work with. It wasn’t until the 1920s and 1930s that scientists discovered ways to plasticize PVC, improving its flexibility and durability. These discoveries made PVC commercially viable, and by the 1940s, it had become an important material for construction, wiring insulation, and industrial applications, just to name a few.
During World War II, PVC’s resistance to chemicals and flame made it invaluable for military equipment. This period spurred rapid growth in vinyl production, setting the stage for new innovations in vinyl-based materials, including plastisol.
The Invention of Plastisol
Plastisol was developed as a flexible, moldable version of PVC that could be heated and cured into a permanent form. The key innovation was suspending solid PVC particles in a plasticizer, creating a stable liquid dispersion. When heated, the mixture gels and fuses into a soft, rubber-like plastic that remains permanently flexible. A plasticizer is a chemical added to plastics to make them softer, more flexible, and easier to shape.
This breakthrough opened new doors in manufacturing. Suddenly, companies could mold PVC into complex shapes or vinyl coat irregular surfaces with ease. The formulation was easy to customize, economically cost-effective to produce, and delivered exceptional durability.
While most of our products at Carlisle Plastics are flexible we do work with a “Shore A” Scale of raw materials which we refer to as “Durometer” We normally work the range of 55 – 90 Durometer materials on this Shore A Scale. The lower the number, the more flexible or rubbery the feel. Once we get into the 90 Durometer Range the part becomes more rigid. Not as rigid as say a toothpaste lid, but is no longer “flexible”.
Plastisol in the 1950s and 1960s
The mid-20th century saw a boom in plastisol applications. Dip molding became a go-to techniques for manufacturers looking to produce soft-touch parts, flexible and rigid parts, electrical insulation, and industrial grips.
In these processes, plastisol was poured or dipped over molds and then heated to achieve a perfect fit. Unlike rigid plastic molding, plastisol molding didn’t require high-pressure systems, reducing tooling costs and increasing manufacturing flexibility. As demand for consumer and industrial plastics soared, plastisol became a cornerstone of vinyl manufacturing.
Carlisle Plastics Company was founded during this era, growing alongside the expanding role of vinyl in American industry. Our company has proudly specialized in plastisol dip molding caps and vinyl coatings from the beginning.
Refinements in Plastisol Formulation
Advances in chemistry and manufacturing have led to more precise plastisol formulations over the decades. Manufacturers can now adjust plastisol to meet specific requirements for flexibility, hardness, color, thickness, and UV resistance.
Carlisle Plastics Company has been a pioneer in offering custom plastisol dip molding solutions tailored to customer specifications. From thick coatings for heavy-duty equipment to soft finishes for consumer products, we’ve helped businesses across industries benefit from the adaptability of plastisol in dip molding.
We also color match to Pantone or customer provided color samples. We also can offer products that are “glow in the dark”, contain metallic flakes, translucent, etc.
Environmental and Regulatory Considerations
As environmental awareness has grown, so too has the scrutiny of plastic materials, including PVC and plastisol. In response, the industry has made significant strides in improving the safety and sustainability of plastisol-based products.
Today, plastisol formulations are carefully engineered to meet or exceed health and safety regulations. Carlisle Plastics Company is committed to using high-quality, compliant materials and continuously evaluating our processes to reduce environmental impact. We also offer low-VOC and phthalate-free plastisol options for clients with specific regulatory needs.
Plastisol Today and Beyond
Modern plastisol continues to be a material of choice for industries ranging from automotive to marine, medical to fashion. Thanks to its unmatched flexibility and performance, plastisol is still growing in relevance after nearly 70 years of use.
At Carlisle Plastics Company, we see plastisol not just as a product, but as a solution. Our decades of experience and investment in improving manufacturing techniques allow us to offer world-class plastisol dip molded products to customers across North America and beyond.
As new applications for plastisol emerge and industries continue to demand higher performance from their materials, we remain committed to innovation, quality, and customer service.
Interested in Plastisol Solutions? Let’s Talk.
Whether you’re looking to learn more about plastisol caps, coatings, or ready to start a custom project, Carlisle Plastics Company is here to help assist.
We welcome questions, consultations, and challenges—and we’ll do whatever it takes to help the customer find a dip molded solution that fits their project needs, as long as it’s within our capabilities.