Plastisol is a compound made of PVC particles and plasticizers that increase its fluidity. It can be heated, melted, and shaped for stamping, casting, textile inks, and screen printing. Plastisol is a good candidate for slush molding and casting and is commonly used for screen printing and textile inks. It is not water-soluble and has low health risks, flammability, and reactivity. Screen printed fabrics must withstand the heat required to cure plastisol inks and provide a porous surface for the compound to adhere to.
Plastisol is a compound based on various resins mixed with plasticizers, which are intended to increase the fluidity of the resins. The resin is usually made from particles of polyvinyl chloride (PVC), a plastic polymer that contains a series of vinyl groups or carbon-carbon double bond units. After mixing the particles with the plasticizer, the compound can be heated, melted and shaped. Applications of plastisol include stamping, casting, textile inks and screen printing.
Because the plasticizer is able to increase the elasticity of the vinyl polymer, the two can form a liquid upon heating. The plastisol is completely melted and mixed at a temperature of 350.6°F (about 177°C), at which point it can be placed in a mold to cool. By the time the temperature reaches 140°F (about 60°C), the plastic has set and formed a solid, pliable object. In addition to PVC resins, other plastics may be added, but the plastisol will still remain a fully solid compound after curing.
This molding practice makes plastisol a good candidate for slush molding and casting, processes used to create detailed molded products. The liquid plastic compound is placed into a metal mold, which is then spun at high speed. Spinning uses centripetal force to press the liquid into the smallest spaces of the mold and ensure uniform contact. Once spun, the mold can be heated to harden the material, as metal molds are not adversely affected by heat in the same way as more flexible resin molds. Slush molding is generally believed to create more complex molds than the simpler rotary casting practices, but is less detailed and less expensive than plastic injection molding techniques.
Plastisol is also commonly used for screen printing and textile inks because it is not water soluble and does not require a washing process after printing. The compound is also considered relatively safe and has a health risk rating of one, indicating it is only mildly hazardous. Flammability and reactivity are also low, as are potentially harmful solvents within the plastic blend and the presence of volatile organic compounds (VOCs).
The main requirements of screen printed fabrics are that they can withstand the heat required to cure plastisol inks and that they can provide a sufficiently porous surface for the compound to adhere to. Unlike dyes, plastic textile inks are not absorbed by the fibers of the fabrics. Instead, they bond with the fibers and form a coating around them, which is why a porous surface is needed for a strong seal.
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