In the distinctive world of designer toys, creative artists use toys as a medium to express their observations and reflections on the world around them. The journey from abstract concept to tangible product relies heavily on the choice of materials and production processes—which not only bridge the gap between the creator and the collector but also profoundly shape the collector's interaction with the finished piece.
The Vinyl Process
Vinyl is a manufacturing technique with a long and storied history. The first vinyl machine was built in Germany in 1924, and the very first vinyl toy ever produced was a chocolate bunny. For many who grew up with a love for toys, vinyl holds a special place in their memories—think of the little yellow duck that floated beside you during bath time. These soft, squeezable, smooth hollow toys are classic examples of vinyl production. While vinyl toys have a distinctive feel and are often mistaken for being made from a unique material, they are actually produced from a type of soft plastic known as PVC.
Vinyl is not a material.
It is important to clarify that vinyl is not a material—it is a manufacturing process. The term "vinyl" originates from the method in which a colloidal PVC substance is evenly distributed across the inner surface of a mold through centrifugal rotation. PVC serves as the raw material for the vinyl process and comes in two basic forms: rigid and flexible. "Sofubi" is the Japanese term for "soft vinyl," also referred to as soft gelatin or Japanese soft gelatin.
Handmade vinyl toys
The price of Sofubi toys has risen over the years, partly due to their "handmade" appeal. The Sofubi process closely resembles the standard vinyl process. The procedure begins by placing the colloidal PVC into the mold, then sealing it shut. The mold is subsequently placed in a high-temperature rotocast oven and rotated at a low speed along two vertical axes. This rotation, combined with gravity, ensures that the molten plastic material forms a uniform coating on the mold's inner walls. Once cooled, the finished product is removed from the mold. The main distinction between the Sofubi process and the standard vinyl process lies in the heat-curing stage. The overall quality of a vinyl toy is also highly dependent on precise control of timing and temperature throughout these phases.
Time-consuming, labor-intensive and costly mold-making
High-volume production relies heavily on molds. The vinyl process demands high temperatures, so the metal molds are typically made of copper. With the rise of 3D printing technology, many art toy designs are now modeled digitally, and master samples are directly 3D printed. However, in the traditional vinyl process, mold creation is far more complex and is generally divided into two stages: clay sampling and wax sampling.
First, a clay model is shaped—both by hand and by machine—to create an initial prototype of the design. Next, a wax model is produced based on the clay prototype. Because approximately 3% shrinkage occurs during the subsequent mold‑conversion process, the wax model is deliberately made larger to compensate and achieve the desired final dimensions.
Why use wax models? On one hand, the surface of a wax model is easier to polish, resulting in a smooth, flat finish for the mold. On the other hand, this stage follows a method similar to the ancient "lost‑wax" technique used in bronze casting. The wax models are placed in an electroplating tank, where copper molds are formed through an electrolytic reaction. The mold is then heated, causing the wax to melt away and leaving a hollow copper mold with a negative impression of the wax model. This copper mold is referred to as the "master mold."
Even in mass production, metal molds undergo wear and tear and eventually become obsolete. For this reason, multiple production molds are often derived from these master molds. The production molds are then welded to steel frames, which facilitates the shaping of mass‑produced items.
Advantages and disadvantages of vinyl toys
By visualizing the flow of colloid inside the sealed mold, we can better understand the various strengths and weaknesses of the vinyl process. One of its greatest advantages is the absence of parting lines—a common flaw in injection molding. Because the vinyl mold is made as a single piece, it can produce finished products free from such seam marks. Additionally, vinyl toys are typically hollow, thanks to the centrifugal force generated during rotation. This makes them lightweight, elastic, difficult to break, and easy to handle—ideal for playing, carrying, and even outdoor photography. Beyond their collectible value, they also offer a sense of companionship and social function, which may explain why many designer toys are produced using the vinyl process.
However, the process does have its limitations. First, vinyl imposes certain design constraints. If a shape features many sharp protrusions and deep recesses, the flow of colloid inside the mold will be obstructed, leading to defects such as air bubbles or material shortages. This is why most vinyl toys tend to have simple, rounded silhouettes without sharp corners.
Second, almost every step of the process—aside from copper mold plating—is done manually. This includes timing the molding cycle, removing the product from the mold by hand, and painting each piece individually. Since the shapes of soft vinyl toys vary widely, automated machine painting is not feasible. As a result, there is a high degree of inconsistency in the finished products, a significant rejection rate, and elevated labor costs.
Finally, because vinyl toys are made from PVC plastic, they are susceptible to warping, cracking, and plasticizer migration (often referred to as "oil bleed"), which are common issues associated with PVC materials.
There is no absolute superiority or inferiority when it comes to materials or production methods; each is chosen to complement specific products and creative expressions. The inherent imprecision of vinyl toys is, in fact, a key part of their charm and value. Moreover, the vinyl process—with its hand‑coloring techniques—affords designers even greater creative freedom. This has led to the creation of many unique, limited‑edition pieces, further enhancing their rarity and desirability among collectors.