For anyone wondering how the metal molds are made themselves, its a copper electroforming process, they put a conductive paint or laquer on the wax cast of the toy and electroplate copper to it until it is thick enough to hold its own shape, the wax is then melted out. Hilarious part for me is i spent a few years trying to figure out how the molds themselves were made even as i was working professionally AS an electroplater, for hexavalent chromium specifically. Went over my head completely as a posibility lol
Thank you so much Andy. It's such a rare treat to see these artisans at work. They do what is so easily taken for granted. Hopefully there will always be others learning the trade to carry the torch of the craft of Sofubi. Skullbrain: ZombieDaddy
Pretty sure it's not a chemical bath. Looks more like it's cold water to cool the mold and the hot liquid vinyl so it sets up? At no time does the liquid touch the vinyl in the mold.
I love that there is becoming more info available about his process! I would like to try it in my garage, seems like something that would open up vinyl toy making to very new would-be toy producers. Do you know what liquid is being used in the hot-bath to get the vinyl to kick?
Great video. How do they pull the shapes from such small openings in the moulds? Is the vinyl used hardened to a degree (enough to have shape memory) but still soft enough to pull through the hole without creasing, or am i missing something?
The vinyl is very soft at the pulling stage, so they grab the top with tongs and slowly pull it out of the opening, to avoid ripping or damage in the process. By then the shape memory is established, and it retains the mold shape while hardening.
hi, do you know the process in which they "inject" soft vinyl to make figures? do you maybe have a video, i want to make some figures but im having problems "cooking" them, thanks!
I've written some posts about the toy making process on Kaiju Korner (kaijukorner.blogspot.com). Besides that I heard there were one or two US outfits that are/were making their own vinyl toys. You might be able to track them down via Google.
Not sure if they're still running. I was only able to go as a guest of a toy maker. Only time I've been able to visit and film a factory as they worked.
QuailStudio It isn't in central Tokyo. I can't remember exactly where. I should emphasize this is not a factory open to all visitors. It's a business, and I could visit since I was there with one of their customers. Anyway, happy new year! :)
Sadly, Admiral Perry put an end to the traditional Japanese way of making vinyl toys in 1868, when he forcibly opened re-Japan to trade with the West. Japanese vinylcraft techniques which had originated in the early Edo period and had been preserved more or less intact for almost 300 years by a rigid patronage system, were no match for a flood of cheap vinyl products from America.
Actually the original method of making vinyl toys in Japan died with the advent of feudalism in the late 12th century. All proceeding forms of vinyl crafting are mere mockeries of the original.
To my knowledge, the molds are made of brass/copper by master craftsmen. It's a world very few people are privy to, and unfortunately I've never even heard of a video of such a place or artisan at work. I can tell you they use wax casts to produce the molds. Hope that helps some.
KaijuKornerAndy After pattern making you have silicon rubber casting (probably wax rather than resin) to produce multiple copies from the master, then the wax copies need to be used to produce PVC molds. The mold making is usually some sort of lost wax casting, and only part of the model fabrication process that's not really manageable by a garage company, hence my interest in finding out how they had gotten that done. This high temperature mold making/transferring process is not included in traditional western model making, and is why we don't see american or european made PVC model kits. It's a more industrialized production method, like injection plastic, and beyond the financial parameters of normal garage companies.
I hear what you're saying, and yes that's right, the brass molds are made using a lost wax method by expert artisans. Basically what you're looking at in this video is a "factory" using traditional methods to make toys one part at a time. But the quality is high. And the molds they use are top notch. (So are the masks used by toy painters.) The cost of producing the molds and paint masks is one of the most expensive elements involved with making these toys. Everything I'm talking about is related to soft vinyl (aka sofubi) toy making. I really couldn't speak to what's involved in making PVC toys or models, or how you might get that done cheaply.
KaijuKornerAndy PVC = polyVINYL chloride Material and fabrication costs aside, Japanese labor had gone up a lot, reflected through the lack of complexity and intricacy in their finished vinyl toys. Anyroad, thank you for the clarification. I had always wondered if they had outsourced to get the pvc molds made. That's gotta be expansive :O
Just to clarify, the toys I'm talking about (and which are shown in the video) are not made of PVC, which is a very hard finished product. They're made of soft vinyl, which, even after the vinyl dries, remains soft and squishy to varying degrees.
I’ve been researching this. It must be pretty hot. The liquid “vinyl” is plastisol. A pvc suspension. When heat is added the pvc particles swell and absorb the plasticizer (plasticizer makes it a liquid). With the plasticizer absorbed the material begins to gel the solidify. My guess it the chemical is an oil or other material that can withstand high temps. Plastisol sets at about 350 degrees.
Cristopher Diño I am almost certain it is. Maybe a little different in its viscosity etc. there have been several people who have tried to start companies like this in the US and they’ve all failed bc the FDA and OSHA have issues with the chemical used in the heated bath. This is at least what I was able to find out.
Cristopher Diño pretty sure the bath only heats the layers in contact with the metal mold. An oven would also set the top opening where you’d pour out the excess material. That’s my theory
*Well this told me nothing! So he is pouring the vinyl... [How is vinyl made? What is its cchemical components? What is its viscosity] ...There's a centrifuge and it goes int he centrifuge... [What is the mould made from? how hot does the mould get?] ...And it comes out of the centrifuge into a chemical bath... [What is the chemical in the Bath? Why does it need to go in that?] ...And then the excess vinyl pored out, and back in the chem bath. And then in a different chemical bath [What chemical is that? What does it do?] .....And thats it.*
For anyone wondering how the metal molds are made themselves, its a copper electroforming process, they put a conductive paint or laquer on the wax cast of the toy and electroplate copper to it until it is thick enough to hold its own shape, the wax is then melted out. Hilarious part for me is i spent a few years trying to figure out how the molds themselves were made even as i was working professionally AS an electroplater, for hexavalent chromium specifically. Went over my head completely as a posibility lol
I've also heard that they often place a nickel layer into the wax dummy first (before the copper) as it aids the removal of the vinyl piece.
@@MoonlightFox yes i've heard something similar as well, most likely a layer of nickel first and then copper plated on top afterward
Haha bro your a legend it's EXACTLY what I was wondering
Thank you so much Andy. It's such a rare treat to see these artisans at work. They do what is so easily taken for granted. Hopefully there will always be others learning the trade to carry the torch of the craft of Sofubi.
Skullbrain: ZombieDaddy
Not much to it, really.
Nice to have someone upload stuff like this. Much appreciated.
That was awesome to watch. Thanks for sharing that with us.
great vid man, i appreciate the upload!
Thanks Eddie!
this is 2019. I wonder if this factory in still in business.
Pretty sure it's not a chemical bath. Looks more like it's cold water to cool the mold and the hot liquid vinyl so it sets up? At no time does the liquid touch the vinyl in the mold.
Hard to say - I might try to set up a couple of interviews with toy makers next month.
Very interesting
--- thanks for sharing👍
I love that there is becoming more info available about his process! I would like to try it in my garage, seems like something that would open up vinyl toy making to very new would-be toy producers.
Do you know what liquid is being used in the hot-bath to get the vinyl to kick?
typically doll parts made from vinyl is cooled in plain water. no extra chemicals needed.
They use water bath to cool down the metal molds and vinyl. When vinyl is cool it is cured.
Wish you made new videos ...
que envidia saber el proceso del sofubi..interesante video!
Great video.
How do they pull the shapes from such small openings in the moulds?
Is the vinyl used hardened to a degree (enough to have shape memory) but still soft enough to pull through the hole without creasing, or am i missing something?
The vinyl is very soft at the pulling stage, so they grab the top with tongs and slowly pull it out of the opening, to avoid ripping or damage in the process. By then the shape memory is established, and it retains the mold shape while hardening.
i have searched for years and cant figure out whats the exact chemical bath components of the bath any info on whats in it ?
Anyway you get the info where is located thanks :)
i hope this toy factory will make kaiju grugio bone heleboros figure 6inches
What vinyl figure were they making
but how they made the molding thing
hi, do you know the process in which they "inject" soft vinyl to make figures? do you maybe have a video, i want to make some figures but im having problems "cooking" them, thanks!
I don't have a video or info on that process. Good luck!
what liquid in bath? can make high temperature for mold.
I've written some posts about the toy making process on Kaiju Korner (kaijukorner.blogspot.com).
Besides that I heard there were one or two US outfits that are/were making their own vinyl toys. You might be able to track them down via Google.
Amaría hacer una producción de toys en este lugar😻
no heat cure? I'm assuming they're using plastisol.
Never assume.
where is the final toy?
Sir can send me how to make meterial PVC liquid
So this is how they make kamen rider and super sentai figure
Do you now if this factory is still running, I'd love to go visit.
Not sure if they're still running. I was only able to go as a guest of a toy maker. Only time I've been able to visit and film a factory as they worked.
was this in Tokyo, or some country side ?
QuailStudio It isn't in central Tokyo. I can't remember exactly where. I should emphasize this is not a factory open to all visitors. It's a business, and I could visit since I was there with one of their customers. Anyway, happy new year! :)
Sadly, Admiral Perry put an end to the traditional Japanese way of making vinyl toys in 1868, when he forcibly opened re-Japan to trade with the West. Japanese vinylcraft techniques which had originated in the early Edo period and had been preserved more or less intact for almost 300 years by a rigid patronage system, were no match for a flood of cheap vinyl products from America.
Actually the original method of making vinyl toys in Japan died with the advent of feudalism in the late 12th century. All proceeding forms of vinyl crafting are mere mockeries of the original.
where i can contact that factory?
Hi, Andy,
Have any video that could show us how wax or resin patterns were transferred into these high temperature PVC molds (are they cast iron)?
To my knowledge, the molds are made of brass/copper by master craftsmen. It's a world very few people are privy to, and unfortunately I've never even heard of a video of such a place or artisan at work. I can tell you they use wax casts to produce the molds. Hope that helps some.
KaijuKornerAndy
After pattern making you have silicon rubber casting (probably wax rather than resin) to produce multiple copies from the master, then the wax copies need to be used to produce PVC molds.
The mold making is usually some sort of lost wax casting, and only part of the model fabrication process that's not really manageable by a garage company, hence my interest in finding out how they had gotten that done.
This high temperature mold making/transferring process is not included in traditional western model making, and is why we don't see american or european made PVC model kits. It's a more industrialized production method, like injection plastic, and beyond the financial parameters of normal garage companies.
I hear what you're saying, and yes that's right, the brass molds are made using a lost wax method by expert artisans.
Basically what you're looking at in this video is a "factory" using traditional methods to make toys one part at a time. But the quality is high. And the molds they use are top notch. (So are the masks used by toy painters.)
The cost of producing the molds and paint masks is one of the most expensive elements involved with making these toys. Everything I'm talking about is related to soft vinyl (aka sofubi) toy making. I really couldn't speak to what's involved in making PVC toys or models, or how you might get that done cheaply.
KaijuKornerAndy
PVC = polyVINYL chloride
Material and fabrication costs aside, Japanese labor had gone up a lot, reflected through the lack of complexity and intricacy in their finished vinyl toys.
Anyroad, thank you for the clarification. I had always wondered if they had outsourced to get the pvc molds made. That's gotta be expansive :O
Just to clarify, the toys I'm talking about (and which are shown in the video) are not made of PVC, which is a very hard finished product. They're made of soft vinyl, which, even after the vinyl dries, remains soft and squishy to varying degrees.
Como se pintan???
Hi what is name hot liquid
Poor Oji-san! his wife keeps pointing out flaws in his work!
Don't worry they make like 1000 dollar for it so don't worry
Hello I need help from you I what make PVC toy mannequin hand please send me material list and ratio and temperature and time please reply
So awwsomeeee. .... Can you tell me about the material of little duck...
Hendrawan Lie The toys there are made of soft vinyl, aka "sofubi."
PVC same of soft vinyl ?
I think it's similar, but I don't know the exact chemical composition.
Plastisol. It’s a pvc resin suspended in plasticizer. The bath they dip in is heated which solidifies the pvc.
Cool thanx... next video?
I from india
Itokin Park Lucha Bears
140 gram component
what kind of liquid is that to make sofubi n wht chemical to dip in
I’ve been researching this. It must be pretty hot. The liquid “vinyl” is plastisol. A pvc suspension. When heat is added the pvc particles swell and absorb the plasticizer (plasticizer makes it a liquid). With the plasticizer absorbed the material begins to gel the solidify.
My guess it the chemical is an oil or other material that can withstand high temps. Plastisol sets at about 350 degrees.
@@bamfett1 Is it plastisol? as in, the plastisol ink used to print t-shirts? I wonder where i can but this material
Cristopher Diño I am almost certain it is. Maybe a little different in its viscosity etc. there have been several people who have tried to start companies like this in the US and they’ve all failed bc the FDA and OSHA have issues with the chemical used in the heated bath. This is at least what I was able to find out.
@@bamfett1 Why do they need to use heated bath. Can they just use oven? plastisol can cure in any source of heat right?
Cristopher Diño pretty sure the bath only heats the layers in contact with the metal mold. An oven would also set the top opening where you’d pour out the excess material. That’s my theory
*Well this told me nothing! So he is pouring the vinyl... [How is vinyl made? What is its cchemical components? What is its viscosity] ...There's a centrifuge and it goes int he centrifuge... [What is the mould made from? how hot does the mould get?] ...And it comes out of the centrifuge into a chemical bath... [What is the chemical in the Bath? Why does it need to go in that?] ...And then the excess vinyl pored out, and back in the chem bath. And then in a different chemical bath [What chemical is that? What does it do?] .....And thats it.*