How Are Soft Vinyl Figures Made?

Soft vinyl figures, also known as sofubi (short for soft vinyl in Japanese), have captivated collectors, artists, and toy enthusiasts worldwide with their unique combination of flexibility, durability, and artistic appeal. Unlike rigid PVC figures, soft vinyl figures are lightweight, slightly squishy to the touch, and often hand-painted to showcase intricate details. This article explores the entire process of creating these charming collectibles, from concept to finish, while highlighting their distinct features and advantages.

What Are Soft Vinyl Figures?

Soft vinyl figures are toys and collectibles molded from a special flexible type of vinyl, giving them a distinct tactile experience. Originating in Japan, sofubi figures traditionally used techniques dating back decades, but modern advancements have enhanced their quality and production methods.

Key Characteristics

• Soft, flexible texture: Unlike their hard PVC counterparts, soft vinyl figures have a pliable, squeezable feel.

• Lightweight and hollow: Made hollow through a rotational molding process, these figures are easier to handle.

• Multi-part assembly: Most are produced in separate pieces (e.g., head, limbs, torso) which are assembled post-production.

• Vibrant, hand-painted finishes: Hand-painting adds uniqueness and artistic value.

• Strong retro and nostalgic appeal: Sofubi draws from traditional Japanese designs, fostering a dedicated collector community.

Soft vinyl figures differ notably from PVC figures in their flexibility and artistic suitability. While PVC is better for mass production of rigid toys, soft vinyl’s texture and molding process accommodate artistic expression and customization.

The Soft Vinyl Figure Production Process

Creating a soft vinyl figure is a meticulous blend of art and manufacturing technology. Each step is crucial to ensuring the figure’s quality, flexibility, and aesthetic value.

1. Designing and Prototyping

The process begins with the creative phase:

• Conceptual design: Artists sketch the character and decide on proportions and style.

• 3D prototype creation: This can be sculpted by hand or modeled digitally using 3D software.

• Prototype refinement: This stage ensures the design functions well for molding and assembly.

2. Mold Making

Once the prototype is approved, the master mold is created:

• Wax sample production: A wax model replica of the prototype is made as part of the lost wax casting process.

• Electroforming: The wax model is coated with metal (usually copper) via electroplating, then the wax is melted away, leaving a hollow copper mold.

• Metal molds: These are highly durable and can include complex shapes with undercuts.

This traditional method allows precise detail and durability in molds, setting soft vinyl apart from injection molded plastic toys.

3. Rotational Molding of Vinyl

Soft vinyl figures are produced using a technique called rotational or rotocasting molding:

• Liquid soft vinyl is poured into the metal mold.

• Mold rotation: The mold rotates slowly on two vertical axes inside an oven, ensuring the vinyl coats the mold’s interior evenly.

• Heating and curing: The vinyl layer cures against the heated mold surface.

• Removal of excess vinyl: Any uncured vinyl is drained and reused.

This results in hollow, lightweight parts that retain flexibility and strong details.

4. Cooling and Demolding

After curing:

• The mold is cooled in a water bath to solidify the vinyl.

• The soft vinyl figure parts are carefully removed from the mold to avoid tearing.

At this stage, the vinyl remains soft and flexible, ideal for further assembly and decoration.

5. Assembly of Parts

The separate components produced (head, torso, arms, legs) are:

• Assembled by hand to form the complete figure.

• Sometimes feature interchangeable or posable designs for collectors.

This handcrafted assembly ensures quality and allows custom variations.

6. Hand-Painting and Finishing

The final stage involves meticulously applying colors and finishing touches:

• Skilled painters add vibrant, unique details.

• Some figures use limited-edition paint schemes.

Hand-painting distinguishes soft vinyl figures visually from mass-produced plastic toys.

FAQs About Soft Vinyl Figures

Q1: What makes soft vinyl figures different from PVC figures?
A: Soft vinyl is flexible and hollow, offering a squishy feel and lighter weight, while PVC is rigid and heavier. Soft vinyl is better for artistic, limited-edition designs.

Q2: Why use rotational molding for soft vinyl figures?
A: Rotational molding allows the vinyl to coat the interior of molds evenly, producing hollow, lightweight parts with smooth surfaces and strong detail.

Q3: How are the metal molds for soft vinyl figures made?
A: Using the lost wax method, a wax model is electroplated with copper, melted away, leaving a highly detailed hollow copper mold.

Q4: Can soft vinyl figures be customized?
A: Yes, soft vinyl is easy to cut, paint, and modify, making it popular with artists who create custom toy designs.

Q5: Are soft vinyl figures durable?
A: Despite their softness, these figures are surprisingly durable due to the hollow, evenly formed vinyl and robust mold materials used.