At Carlisle Plastics Company, every cap has a story — starting with liquid plastisol and ending as a tough, flexible, perfectly fitted plastic cap. The process that makes this possible is dip molding.
Dip molding is a reliable and cost-effective way to manufacture protective PVC caps and a wide variety of plastics products. It allows us to create a wide range of shapes, sizes, and thicknesses, serving industries from furniture and automotive to electronics and consumer goods. Whether you need standard sizes or fully custom tooling, dip molding is the foundation of how Carlisle Plastics delivers durable, made-to-order solutions.
What Is Dip Molding?
Dip molding begins with plastisol, a suspension of PVC particles in a liquid plasticizer. When heated to about 350°F (177°C), the PVC fuses into a flexible, rubber-like coating. This material is strong, waterproof, and resistant to wear — perfect for protective caps. Learn more about the history of plastisol here.
The dip molding process works like this:
- Heated mold forms are shaped like the finished part (such as a cap).
- The forms are dipped into liquid plastisol.
- A layer of plastisol sticks to the mold and gels.
- The coated molds are baked, curing the plastisol into solid PVC.
- After cooling, the formed parts are stripped from the molds.
The result is a seamless, flexible cap ready to protect, seal, or finish a product.
Advantages of Dip Molding
Dip molding is trusted because it offers several benefits:
- Design Flexibility: Almost any shape can be produced, from round caps to flat, angled, or rectangular profiles.
- Durability: Dip-molded PVC resists abrasion, moisture, and chemicals.
- Cost-Effective Tooling: Unlike injection molding, dip molding requires simpler tooling, keeping costs lower.
- Smooth Finish: The process produces uniform, glossy, or textured finishes for both function and appearance.
- Custom Thickness: By controlling dip time and temperature, we can adjust wall thickness for different needs.
Standard Sizes, Custom Results
While every Carlisle Plastics cap is made to order, we maintain a large inventory of standard production dies. This means we can produce many popular sizes without the need for new tooling.
For customers, this offers:
- Faster turnaround on common shapes and dimensions.
- No added tooling cost for standard parts.
- Reliable sizing that fits industry needs.
These standard sizes cover a wide range of applications, from finishing furniture legs to capping industrial tubing.
When Custom Tooling Is Needed
Not every project fits a standard die. That’s why Carlisle Plastics Company also offers in-house custom tooling. Our tool shop designs and manufactures new molds to match your exact specifications.
Custom tooling is often requested for:
- Specialized equipment with unique dimensions.
- Complex shapes beyond standard caps.
- Applications that require branding, textures, or unique finishes.
This balance — standard sizes for efficiency and custom tooling for precision — ensures we can serve every industry need.
Industries That Rely on Dip-Molded Plastic Caps
Dip molding allows Carlisle Plastics Company to serve a wide variety of industries, including:
- Automotive: End caps for tubing, protective covers for fasteners, and finishing touches for interiors.
- Furniture: Caps for chair legs, shelving, and office equipment that protect both products and floors.
- Electronics: Insulating caps for wiring, connectors, and delicate components.
- Industrial Equipment: Protective covers for tools, fittings, and exposed metal.
- Consumer Goods: Caps that add comfort, safety, and style to everyday products.
Because all products are made-to-order, clients can choose standard dies for efficiency or custom designs for one-of-a-kind applications.
Why Plastisol?
Plastisol is at the core of the dip molding process. Its properties make it ideal for caps:
- Flexible and impact-resistant.
- Waterproof and protective against corrosion.
- Available in a range of colors and finishes.
- Cost-effective for both small and large runs.
These qualities allow us to manufacture caps that don’t just fit — they last.
The Carlisle Plastics Company Difference
What sets Carlisle Plastics Company apart isn’t just dip molding. It’s how we combine craftsmanship with flexibility:
- Made-to-Order: Every cap is produced specifically for the customer’s request.
- Standard Dies: Fast, affordable options using our extensive library of existing sizes.
- Custom Tooling: Full in-house design for unique applications.
- Family-Owned Service: A commitment to quality and relationships built over decades.
- Durable Results: PVC caps that perform in demanding industrial and consumer environments.
From Liquid to Legacy
Dip molding may start with liquid plastisol, but it ends with more than just plastic. It produces parts that protect, enhance, and extend the life of products in industries around the world.
At Carlisle Plastics Company, every cap we make carries the same promise: made-to-order, built to last, and crafted with care. Whether you choose from our wide range of standard sizes or request a fully custom design, the result is the same — precision, protection, and performance.
Built to Fit, Built to Last
From forest machines to office furniture, every industry needs protection and finishing solutions. Dip molding makes it possible, and Carlisle Plastics Company makes it reliable.
Because when it comes to plastic caps, one size doesn’t fit all — but Carlisle Plastics Company makes sure the right one fits you.
If you have questions, we are here to help, contact Carlisle Plastics Company today!