The production of PVC badges (soft rubber badges) usually adopts the molding process

The production of PVC badges (soft rubber badges) usually adopts the molding process, which is suitable for making three-dimensional, colorful and durable products. The following is a standard and complete production process in the industry, for your reference.

一、Preparation

Design file: provided by customer AI / CDR / PDF Wait for vector files, specify dimensions, color (usually refer to Pantone color number), thickness, and back processing.

Process evaluation: Confirm whether it is suitable for PVC process (line thickness, minimum spacing, number of colors).

3D effect splitting: layering different colors and heights according to patterns.

Sample confirmation: Make a sample for the customer to confirm the color, three-dimensional effect, and overall texture.

Mold material: Usually copper mold or aluminum mold.

Carving method: CNC precision carving or electrical discharge machining.

Mold structure: divided and layered according to design to ensure that different colors do not mix.

Mold inspection: Confirm that the lines are clear and the depth is consistent.

二、 Production process flow

3. PVC raw material blending

Raw material composition: PVC powder, plasticizer, stabilizer, color powder.

Color matching: manual or machine color matching according to Pantone color number.

Softness and hardness control: control the softness of the finished product through the proportion of plasticizers.

Color separation injection: Inject liquid PVC color by color according to the mold division.

Layered operation: first the lower layer, then the upper layer, to avoid color mixing.

High manual precision is required: this process directly determines the appearance quality of the finished product.

Temperature range: about 160– 200°C.

Time control: Adjust according to thickness and number of layers.

Objective: To completely cure and set the PVC.

Mold removal: manually removed after cooling.

Edge trimming: Trim excess edges to ensure neat edges.

Glue / Clear Coat: Enhance gloss and wear resistance.

Matte treatment: to create a more sophisticated or industrial look.

Printing or embossing: used to add detailed text or logos.

Common back forms include:

sticky

Velcro (smooth surface / rough surface)

pin

Keychain

Zipper head, hanging rope hole, etc.

IV. Quality Control

9. Full inspection or spot inspection

Is the color accurate?

Is the pattern clear?

Are there bubbles, deformation, or dirt spots?

Is the back piece sturdy?

Single OPP bag (regular)

Cardboard + OPP bag (retail)

Customized packaging (gift boxes, blister packaging, etc.)

V. Production cycle reference

Sample: 5–7 days

Mass production: 10–15 days (depending on quantity and complexity)

Mold life: reusable, suitable for long-term orders

VI. Summary of Characteristics of PVC Badges

Strong sense of three-dimensionality, high color saturation

Waterproof, sunscreen, wear-resistant

Suitable for anime, fashion brands, tactical armbands, promotional gifts, etc.

The unit price varies greatly with the size, color quantity, and thickness.