Step 1: Surface Preparation

• Cleaning & Degreasing:
  • Use alkaline cleaners, solvents, or ultrasonic degreasing to remove oil, grease, and contaminants.
• Abrasion (if required):
  • Sandblasting or grit blasting improves mechanical adhesion.
• Priming (if needed):
  • Some materials, like aluminium or stainless steel, may require a primer to enhance adhesion.

Step 2: Preheating the Component

• The metal part is preheated in an oven at 150–230°C
• The preheating temperature depends on the desired coating thickness:

Step 3: Dip Coating

• The hot component is dipped into a bath of liquid PVC plastisol.
• The plastisol gels and adheres to the preheated surface due to heat absorption.
• Dwell time in the plastisol bath controls coating thickness.

Step 4: Draining & Gelling

• After dipping, the part is removed, allowing excess plastisol to drip off.
• Gravity and viscosity affect coating uniformity.

Step 5: Curing (Fusion Process)

• The coated component is placed in an oven at 180–220°C (350–425°F).
• The plastisol fully fuses into a tough, flexible plastic coating.
• Proper curing prevents defects like bubbles, under-curing, or poor adhesion.

Step 6: Cooling & Finishing

• The coated part is cooled in air or water.
• Additional trimming, masking, or secondary processing may be performed.